Tokenizer vocabulary size is a foundational design choice in large language model (LLM) infrastructure, yet it is typically fixed at training time based on convention rather than deployment analysis. We show that the cost-optimal vocabulary is not a constant but a function of the serving regime. We formalize total deployment cost as
Clifecycle(V)=Ctrain(V)+λ⋅Cinfer(V,B), where
λ is inference volume and
B is the serving batch size. Through controlled experiments on two GPU families spanning the memory-bound to compute-bound regimes (A10G, ridge
≈ 117 FLOP/byte; A100, ridge
≈ 183 FLOP/byte), we demonstrate: (1) the inference-optimal vocabulary shifts 16x with serving batch, from 32k at
B=1 to 524k at
B=64+, driven by amortization of the
V×d unembedding matrix read; (2) at 1.3-2.3B model scale, quality (bits per byte, BPB) is optimized at
V=65k, confirming scale-dependent vocabulary preference; (3) the lifecycle-optimal vocabulary diverges from training-optimal by up to 16x for production deployments. Quality is approximately invariant across the optimal range (
<2% BPB spread), making vocabulary a pure systems optimization with no quality penalty in the measured range. Our results provide actionable capacity planning guidance: on-device deployments (
B=1) should use
V≈32k; datacenter serving (
B≥64,
λ≥10) should use
V≈131-262k.