This paper addresses two important aspects of engineering size effects in miniaturizing metallic components and the modeling thereof. The critical role of processing induced size effects is emphasized, which tend to be easily forgotten in experimental work or engineering interpretations of size effects. The second aspect is related to the need for a rigorous strain gradient enrichment in crystal plasticity modeling, as the result of coarse graining the interaction between discrete dislocations. The physical origin of the energetic enrichment is discussed and its deterministic derivation is briefly confronted with the analogous result obtained from a statistical mechanics analysis.In the past decade, industry is increasingly focusing on the behavior of materials in micro and nano-systems. At the level of many microsystems, metallic structures, and films are used ranging from sizes of a few microns to hundreds of microns. The scientific community has given considerable attention to this subject, in particular in the range where size effects have a dominant contribution.The purpose of this paper is certainly not to review the wide field of research that has permitted to experimentally identify and model size effects in metals. Whereas many explanations have been given for the measured effects (usually ''small is strong''), a number of issues remain at least quantitatively unclear. Different physical phenomena contribute to the reported size effects, whereas the interpretation is usually focusing on a single phenomenon. A quantitative analysis necessitates the complete overview of all contributing effects. To provide the relevant context of this contribution, the reader is referred to papers that either discuss the role of different size effects, [1][2][3][4] or papers that provide the state-of-the-art in higher-order crystal plasticity models. [5][6][7][8][9][10][11][12][13][14][15][16] From the modeling perspective, a large number of strain gradient models have been proposed in the literature, whereby the higher-order terms are largely phenomenological, often lacking a rigorous physical connection with the underlying problem.This paper has therefore a two-fold focus: 1) emphasize the critical role of size effects that tend to be easily forgotten; 2) underpin the need for a specific strain gradient enrichment in crystal plasticity modeling, as the result of coarse graining the interaction between discrete dislocations. The first part of the paper concentrates on the important role of processing-or manufacturing-induced size effects, where the intrinsic role of geometrically necessary dislocations (GNDs) is emphasized. The second part concentrates on the physical justification and interpretation of the energetic higher-order terms in strain gradient crystal plasticity. A deterministic analogy with the work of [17] is given, which fits entirely in an earlier adopted format for the incorporation of internal stress effects in FCC crystals. Most importantly, this paper aims to provide additional insight into the origin o...