Prep the chicken: Pat chicken dry with paper towels, then cut into 1-inch pieces. This helps the coating stick and crisp properly.
Set up your dredging station: In one shallow bowl, beat eggs with 1 tablespoon water.
In another, whisk cornstarch, flour, baking powder, garlic powder, onion powder, salt, and pepper.
Coat the chicken: Dip each piece in egg, let excess drip, then roll in the dry mix. Press lightly so the coating adheres. Place coated pieces on a plate.
Preheat the air fryer: Heat to 390°F (200°C) for 3–5 minutes.
A hot basket equals better browning.
Load the basket: Spray the basket lightly with oil. Arrange chicken in a single layer with space between pieces. Spray tops with oil until lightly coated.
Air fry the first batch: Cook at 390°F (200°C) for 8–10 minutes, flipping halfway and spraying again if any dry floury spots appear.
Chicken is done when golden and reads 165°F (74°C) internally. Repeat with remaining chicken.
Make the orange sauce: While chicken cooks, add orange juice, zest, soy sauce, rice vinegar, honey (or sugar), ginger, garlic, and red pepper flakes to a saucepan. Bring to a simmer over medium heat for 2–3 minutes.
Thicken it: Stir in the cornstarch slurry.
Simmer 1–2 minutes more, stirring, until glossy and thick enough to coat a spoon. Remove from heat and stir in sesame oil. Taste and adjust sweet or tangy notes.
Toss to coat: Transfer crispy chicken to a large bowl.
Pour in enough sauce to coat (you may not need all of it). Toss gently until every piece is shiny.
Serve: Garnish with green onions and sesame seeds. Serve right away over rice with steamed broccoli or snap peas.
Offer extra sauce on the side.