Preheat your oven to 425°F and line a baking sheet with parchment paper. While the oven heats, slice your zucchini into 1/4-inch rounds—uniform thickness is key for even crisping. Pat the zucchini slices dry with paper towels; removing excess moisture prevents steaming and helps them crisp up beautifully.

In a shallow bowl, combine the panko, almond flour, parmesan, salt, garlic powder, and a few grinds of black pepper. Mix thoroughly with a fork to distribute the seasonings evenly throughout the breadcrumb mixture. This dry coating mixture is what creates that satisfying crunch, so make sure everything is well combined.

Beat the egg in a separate shallow bowl until well combined. Working with a few zucchini slices at a time, dip each round into the egg to coat both sides, then immediately transfer to the breading mixture and press gently so the coating adheres evenly. I like to use my fingers to really press the panko mixture onto each slice—it ensures maximum crispiness and prevents the coating from falling off during baking.

Arrange the coated zucchini slices in a single layer on your prepared baking sheet, spacing them about 1/2 inch apart so they bake evenly without crowding. Drizzle the olive oil evenly over all the slices, making sure each piece gets a light coating. The oil helps them brown and crisp up in the oven.

Bake for 8-10 minutes, then carefully flip each zucchini chip using a spatula or tongs. Return to the oven and bake for another 8-10 minutes, until the coating is golden-brown and crispy and the zucchini is tender when pierced with a fork. Watch them toward the end to prevent over-browning—every oven is different, so check at 17 minutes first.

Remove the zucchini chips from the oven and let them cool for 2-3 minutes on the baking sheet so they firm up and become extra crispy. Transfer to a serving plate and serve immediately while still warm, alongside the romesco sauce for dipping.