Preheat the oven to 400°F. Coat a large baking dish with cooking spray.: You should notice the oven warming evenly, the air becoming dry and hot, which sets the stage for roasting the zucchini until tender. The heat encourages the edges to caramelize slightly, adding depth to the vegetable. If the oven is not fully preheated, the shells can turn soggy instead of roasting, so wait until it reaches temperature before baking.
Cut the zucchini in half lengthwise and scoop out the flesh to create boats. Arrange the zucchini halves in the baking dish.: As you slice, the scent of fresh zucchini is subtle and green, and the exposed flesh looks pale and slightly moist. Scooping creates a shallow hollow to hold the filling while preserving the outer wall, which should remain firm to the touch. A common mistake is scooping too aggressively, leading to thin walls that collapse during baking, so leave about a quarter inch of flesh for structure.
Heat the olive oil in a large skillet over medium-high heat. Add the onion and cook until softened, about 4 minutes. Add the garlic and cook for another 30 seconds.: When the oil shimmers, add the diced onion , and you will hear a soft sizzle. The onion should become translucent and slightly sweet, releasing a gentle aroma. Add minced garlic and watch for a golden fringe on its edges which signals readiness. If you let the garlic brown too much, it turns bitter, so keep the heat controlled.
Add the sausage to the skillet and cook, breaking it up with a spatula, until no longer pink, about 5 minutes. Stir in the Italian seasoning, salt, and pepper. Pour in the marinara sauce and simmer for 5 minutes longer.: As the Italian sausage browns, it develops browned bits on the pan, which are flavor gold. Break it into small pieces so each bite has an even meat to vegetable ratio. Adding dried Italian seasoning , salt, and pepper will bloom the herbs in the fat, and pouring in the marinara sauce releases a tomato perfume as it simmers. Simmering melds flavors and reduces excess liquid, preventing a watery filling. A frequent error is rushing this step, which leaves the sauce dilute and the filling bland.
Spoon the sausage mixture evenly into the zucchini halves. Top with shredded mozzarella and grated Parmesan cheese.: Filling the boats distributes savory, saucy meat into each cavity, and as you spoon, you should see the filling settle and the surface glisten. Pile the mozzarella cheese so it blankets the filling and finish with Parmesan cheese to encourage browning and a nutty crunch. Resist overfilling, which can lead to spillage and uneven baking.
Bake for 25 minutes, or until the zucchini is tender and the cheese is melted and golden brown. Sprinkle with chopped parsley, if desired, and serve.: In the oven the kitchen will fill with a rich aroma as cheeses bubble and sugars in the marinara sauce caramelize. Look for gently yielding zucchini when pierced with a fork and bubbly, golden mozzarella cheese on top. Let the dish rest briefly before serving so the filling sets, otherwise it can run and be hard to plate neatly.