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For the safe and efficient operation of concentrator photovoltaic cells and electronic chips, low and uniform temperature should be attained. Therefore, the prime focus of this study is to design the optimal headers and to evaluate the performance of a monolithic double-layer microchannel heat sink (MDL-MCHS) operating under forced convective boiling conditions. The designed and fabricated heat sink was proved to attain a uniform temperature distribution over the entire surface of the MCHS heated wall, in a narrow temperature range around the coolant boiling point. The designs of the MCHS inlet and outlet headers were computationally optimized to avoid flow maldistribution over 10 parallel channels in each layer. Subsequently, an MDL-MCHS with an optimized header was fabricated using a metal 3D printer, and its thermal characteristics were experimentally evaluated in counterflow and parallel-flow …