Preheat the oven to 425°F. Liberally grease two baking sheets with divided olive oil so the fries do not stick. Alternatively, line the baking sheets with parchment paper and grease with olive oil or nonstick cooking spray.
Spread the cut zucchini sticks on a lint-free dish towel or paper towels. Pat dry to absorb excess moisture. Set aside while the breading is prepared.
In a shallow bowl combine the almond flour, parmesan cheese, garlic powder, onion powder, salt, and pepper. In another shallow bowl whisk the egg or egg whites until frothy.
Working with 4-5 zucchini fries at a time, use one hand to dip the sticks into the egg, coating evenly. Use the same hand to transfer the zucchini into the cheese mixture, coating evenly. Arrange the zucchini on the prepared baking sheets so they are near each other, but not touching. In order for the fries to become crisp, there must be room for hot air to circulate around them.
Repeat with the remaining zucchini. Bake for 15 minutes. Remove from oven, use a spatula to flip the fries, and rotate pan 180°. Bake for 10-15 minutes longer, or until zucchini is golden and crisp.
While the zucchini is baking, combine the aioli ingredients in a small food processor and pulse until well combined. Alternatively, finely mince the sun-dried tomatoes and mix with mayonnaise and pepper. Serve the fries with dipping sauce immediately.
Best Tips and tricks
Pat dry the zucchini first before coating with eggs and almond flour parmesan mixture to make sure the breading sticks.
Put your dishes in order to work efficiently and save yourself clean up. Use one hand to go from dried zucchini sticks, eggs, breading, then baking sheet.
Baking directly on a well-greased baking sheet versus parchment yields crispier zucchini fries, but requires a little extra clean up.
Use two baking sheets to make sure the fries are not touching and there's room for hot air to circulate. Otherwise, you will be left with limp zucchini instead of golden and crisp.
While they are baking make the dipping sauce to enjoy immediately out of the oven. Upon sitting, the zucchini will release moisture and soften.
(Nutritional Information calculated without Sun-Dried Tomato Aioli)