Preheat oven to 350 degrees F. Grease a 9×13-inch metal baking pan with nonstick cooking spray. You can line the pan with parchment paper, if desired. Set aside.: The kitchen should smell neutral, with the oven warming evenly and the pan ready to accept batter. Make sure the oven reaches a steady heat before baking, since inconsistent temperature can cause uneven coloring and set. A metal pan promotes crisp edges; lining with parchment helps you lift the bars out for neat slicing. A common mistake is not preheating long enough, which leads to underdone centers while the edges overbake. Check that your oven reads correctly by confirming the temperature if you notice unusual browning patterns.
Place the butter in a medium saucepan and melt over medium heat, stirring often, until it foams, smells nutty, and browns. This will take about 5 minutes. Scrape the browned butter into a large mixing bowl and let cool for 5 minutes.: Listen for a gentle sizzling that turns into tiny popping as moisture leaves the butter . Visually, the butter will foam, then the foam subsides and amber flecks form at the bottom. The aroma shifts from creamy to toasty and almost hazelnut like. Scrape it promptly to stop browning; residual heat can quickly change to burnt. Letting it cool a touch prevents scrambling the eggs in the next step. If you skip constant stirring, you risk burning the milk solids, producing a bitter flavor that ruins the whole batch.
Add the brown sugar and granulated sugar to the brown butter and stir with a wooden spoon or spatula until smooth. Add the eggs and vanilla. Stir until combined.: When you mix the sugars into the warm butter , you should feel a silky, slightly thickened paste that glistens under the light. Adding the eggs and vanilla creates a glossy, cohesive batter that carries a deep, caramel like scent. The mixture should be smooth and homogenous, without streaks of dry sugar. Work gently to avoid whipping in air that could alter the texture. If you pour still very hot butter over the eggs , they can scramble, creating lumps and an off texture.
Add the flour, salt, baking soda, and baking powder. Stir until just combined, don’t over mix.: At this stage, the batter will thicken into a dense, spreadable dough with a matte finish as the flour is incorporated. Fold carefully until you no longer see pockets of dry flour , stopping before it becomes elastic. Overmixing develops gluten, which can produce tough, cake like bars rather than tender ones. You should be able to press a finger gently on the dough and see it hold shape without springing back too much. If you find visible streaks of flour after several folds, mix slowly until they disappear, but refrain from vigorous stirring.
Stir in the chocolate chunks and chocolate chips.: When the chocolate chunks and chocolate chips hit the dough, you will notice the texture become studded and inviting, with dark specks throughout. The dough should be evenly distributed with chocolate so each bite has both gooey and structured chocolate. Use a gentle folding motion to keep the dough tender while ensuring even distribution. A common error is adding too many mix ins which can prevent the bars from setting uniformly in the center; keep the ratio balanced as stated.
Spread the dough evenly in the prepared pan with a spatula. Bake for 18 to 24 minutes or until the bars are set and golden brown. Don’t over bake the bars will continue setting up as they cool.: As the pan goes into the oven the kitchen fills with toasted sugar and butter aromas. Watch the edges as the best visual cue, they should turn a warm golden brown while the center appears set yet slightly shiny. A toothpick inserted near the center should come out with a few moist crumbs but not raw dough. Remove when edges are golden and the center no longer wobbles significantly. Overbaking leads to dry, crumbly bars, so err on the earlier side if unsure; carryover heat will finish the set.
Remove from the oven and sprinkle with flaky sea salt. Let the bars cool before cutting into squares.: Once out of the oven, the surface will settle and emit a deep, caramelized scent. The flaky sea salt will add delicate shards of crunch and bright bursts that contrast with the sweet, nutty base. Cooling is essential to achieve clean slices, as the center firms up and chocolate pockets set. Cutting too soon results in messy squares that do not hold their shape. If you find the bars still too soft after cooling, chill briefly to help with clean slicing.