Preheat the air fryer: Set it to 375°F (190°C) for 3–5 minutes.
A warm basket helps with browning.
Season the meat: In a bowl, combine ground beef, salt, pepper, garlic powder, onion powder, and Worcestershire. Mix gently with your hands or a fork until just combined. Do not overmix or the burgers can turn dense.
Form mini patties: Divide the mixture into 8–10 equal portions (about 1.5–2 ounces each). Roll lightly into balls, then press into 2.5–3-inch patties.
Make a small thumb indent in the center of each to reduce puffing.
Prep the basket: Lightly spray or brush the air fryer basket with oil to prevent sticking. You can also use perforated parchment made for air fryers.
Arrange and cook: Place patties in a single layer with some space between. Air-fry at 375°F for 5–6 minutes.
Check and flip: Flip the patties and cook another 2–4 minutes, depending on thickness and desired doneness.
For food safety, aim for 160°F internal temperature.
Add cheese (optional): In the last 30–60 seconds, top patties with cheese and air-fry just until melted. Remove immediately to avoid overcooking.
Toast the buns (optional): Brush cut sides with melted butter. Air-fry at 350°F for 1–2 minutes until lightly crisp.
Sprinkle with sesame seeds if you like.
Assemble: Layer sauce on buns, add a cheesy patty, then pickles, onion, lettuce, and tomato. Press gently so everything holds together without sliding.
Serve hot: Mini burgers taste best right away. Keep batches warm in a low oven (200°F) if needed.