What are the optimum varchar sizes for MySQL?

Solution 1:

To answer the question, on disk MySql uses 1 + the size that is used in the field to store the data (so if the column was declared varchar(45), and the field was "FooBar" it would use 7 bytes on disk, unless of course you where using a multibyte character set, where it would be using 14 bytes). So, however you declare your columns, it wont make a difference on the storage end (you stated you are worried about disk optimization for a massive table). However, it does make a difference in queries, as VARCHAR's are converted to CHAR's when MySql makes a temporary table (SORT, ORDER, etc) and the more records you can fit into a single page, the less memory and faster your table scans will be.

Solution 2:

MySQL stores a varchar field as a variable length record, with either a one-byte or a two-byte prefix to indicate the record size.

Having a pattern of storage sizes doesn't really make any difference to how MySQL will function when dealing with variable length record storage. The length specified in a varchar(x) declaration will simply determine the maximum length of the data that can be stored. Basically, a varchar(16) is no different disk-wise than a varchar(128).

This manual page has a more detailed explanation.

Edit: With regards to your updated question, the answer is still the same. A varchar field will only use up as much space on disk as the data you store in it (plus a one or two byte overhead). So it doesn't matter if you have a varchar(16) or a varchar(128), if you store a 10-character string in it, you're only going to use 10 bytes (plus 1 or 2) of disk space.