This article reports investigation of the effects of high-rate stochastic micro-mechanics on the produced particulate size distribution during ball milling of reactive bimetallic foils (nanoheaters), by experimental and computational modeling. In particular, Ni-Al foils are ball-milled at various load charges, revolution rates and process durations, and the resulting particulate geometries are characterized by micrograph statistical analysis. Numerical simulation of the evolving particulate structure is based on coalescence and fragmentation of flexible monometallic ellipsoidal primitives, impacted by milling balls and vial walls with kinetic theory-based kinematics. Particulates are constrained by discrete compliant and continuum media and undergo conceptual ideal elastic transformations modeled by strain energy methods, and recast into inelastic frictional and plasticity-driven welding and fracture events. Finally the theoretical model predictions of particulate size distribution are validated against laboratory microscopy observations.