IntroductionAn organism’s thermal biology is determined in part by its size and shape (Angilletta, 2009). For ectotherms, in particular, body surface area and volume mediate the exchange of heat with the environment (Kühsel et al., 2017; Pincebourde et al., 2021). Small-bodied organisms like insects have high surface area-to-volume ratios, and thus experience accelerated heat loss over their proportionally larger body surface (Gunderson, 2024; Kühsel et al., 2017). This relationship is also influenced by morphology, with more elongated body forms having higher proportional surface area than more compact forms (Castro et al., 2021; Okie, 2013). Quantifying these relationships between morphology and thermal biology is essential for predicting differential responses to climate conditions across phenotypically diverse taxa.Biophysical models provide useful frameworks for linking morphology to thermal performance under varying environmental conditions (Johnson et al., 2022, 2025; Stabentheiner & Kovac, 2023; Stupski & Schilder, 2021). Heat budgets, for example, are biophysical models that estimate rates of heat flux attributable to environmental sources (e.g., radiation, conduction, convection) and internal physiological processes (e.g., metabolic heat production, evaporative cooling). Body size and morphology are key parameters in these models because they directly influence rates of heat loss and gain. Specifically, body surface area represents the interface through which insects interact with the thermal environment, regulating the degree of radiative heat gain, convective heat loss to moving air, conductive heat exchange, and evaporative heat loss. Relatedly, body volume and mass determine an individual’s thermal inertia, or the degree of energy required to change body temperature.Consequently, biophysical models depend on our ability to accurately quantify insect size and form. Traditionally, bee body surface area and volume have been quantified indirectly by conceptualizing body segments (tagmata) as ideal solid shapes, for example, by assuming the thorax represents a sphere of a given diameter and estimating surface area and volume from geometric equations (Cooper et al., 1985a; Roberts et al., 1998; Roberts & Harrison, 1999). These methods provide useful alternatives to empirical measurements, which have been hindered by practical difficulties of measuring small, fragile, and complex forms. Consequently, these methods have not yet been empirically validated; the error in geometric size estimates is unknown. Recent advancements in 3D surface modeling of small objects at relatively low cost place these empirical measurements within reach (Doan & Nguyen, 2024; Kühsel et al., 2017; Ströbel et al., 2018). One such technique, photogrammetry, reconstructs a 3D model from a series of 2D images of an object taken from multiple angles. These methods may represent important improvements over traditional geometric estimates that ignore complex variation in 3D morphology (Ostwald et al., 2025).We asked how honey bee (Apis mellifera Linnaeus 1758) size measurements from 3D models differ from those estimated from geometric equations, and what the implications of these differences are for downstream biophysical modelling. Honey bees are a classic model system for understanding mechanisms of thermoregulation insects (Cooper et al., 1985b; Glass et al., 2024; Glass & Harrison, 2024; Roberts & Harrison, 1999; Stabentheiner & Kovac, 2023). We used photogrammetry to construct 3D models of honey bee specimens, from which we collected empirical measurements of body surface area and volume. We compared these measurements to geometric estimates from linear measurements of the same specimens, to estimate the percent error in these estimation methods. Finally, we incorporated our error estimates into a biophysical model using published data for honey bees in flight (Roberts & Harrison, 1999), to understand how size error influences estimates of heat flux across a realistic temperature range. Together, these results clarify the consequences of size assumptions for understanding routes of heat exchange in these ecologically important pollinators.