The study reported herein extends a previously reported "design for mannfacturability" methodology, to forced convection cooled rectangular plate heat sinks, Using a well validated analytical model, the thermofluid performance of the side-inletside-exit (SISE) heat sink has been characterized, parametric optimization carried out, and the maximum heat transfer capabilities fora range of operating points has been determined. A least-material optimization has been performed to achieve optimal material use, The analysis indicates the least-material design to provide significant mass, savings for a moderate penalty in thermal performance. Empirical criteria for manufacturability obtained from several heat sink manufacturers lead to qualitative guidelines.