I'd love to see some real numbers showing how these different decisions impact performance and code size. I suspect the branch cost is pretty minimal because so few of my smallvecs get spilled - so the branch predictor probably does a pretty good job at this.
And there's often fiercely diminishing returns from optimizing allocations. Dropping the number of allocations from 1M to 1k made a massive performance difference. Dropping it from 1k to 1 will probably be under the benchmark noise floor.
It’s possible to implement something like smallvec without the branch by having it always contain a pointer field, which points to either the inline storage or a heap allocation. However this means it can’t be moved in memory (has to be pinned), and also means you can’t reuse the pointer field to be part of the inline storage in the inline case.