This research aims to evaluate the effect of air temperature, irradiation distance, and sonication time on dry characteristics of yellow mealworm (Tenebrio molitor L.) in an infrared dryer (IRD). The design of the drying experiments, which shows the relationship between the input and output variables, was conducted by the response surface method (RSM). The results showed that decreasing irradiation distance, increasing air temperature, and sonication time led to decreasing drying time and specific energy consumption (SEC). The minimum and maximum total color changes were 13.37 and 29.57, respectively. The changes in rehydration ratio (RR) of the samples increased with increasing temperature and sonication time but decreased with increasing irradiation distance, while the results were opposite for ash. The highest amount of protein and the lowest amount of fat were obtained at 70°C temperature, sonication time (30 min), and irradiation distance (15 cm), respectively. The best conditions for drying yellow mealworm include the use a temperature of 70°C, a sonication time of 25.95 min, and an irradiation distance of 11.32 cm, and by applying the optimal conditions for drying time, SEC, color, RR, fat, protein, and ash of the produced dry yellow mealworm are equal to 171.22 min, 61.45 MJ/kg, 14.28, 1.83, 29.09%, 48.13%, and 3.79%, respectively. Practical applications This research helps improve the drying process for yellow mealworms, making it faster and more energy-efficient while preserving their nutritional value. These findings can be applied in the food industry to produce high-quality insect-based protein products for human or animal consumption. Optimizing drying conditions also ensures better color, texture, and rehydration, which are important for consumer acceptance.