Preheat the air fryer: Set to 380°F (193°C). Lightly oil or spray the basket so the skin doesn’t stick.

Pat the chicken dry: Use paper towels to remove excess moisture. Dry skin means better browning and a crisper finish.

Mix the rub: In a small bowl, combine brown sugar, smoked paprika, garlic powder, onion powder, chili powder, pepper, and salt. Add cayenne if you want heat.

Season the thighs: Rub olive oil over the chicken, then coat evenly with the spice mixture on all sides, including under any loose skin.

Arrange in the basket: Place thighs skin-side down in a single layer with a little space between each piece. Don’t overcrowd.

Air fry the first side: Cook for 10 minutes at 380°F. This starts rendering the fat and cooking the meat through.

Flip and sauce: Carefully flip the thighs skin-side up. Brush generously with BBQ sauce. Cook another 7 to 9 minutes, until the skin is crisping and the sauce is glossy.

Finish and check temp: Brush on a second light coat of BBQ sauce and cook 2 to 4 more minutes. The internal temperature should reach at least 175°F on a meat thermometer. Thighs are best around 180–195°F for maximum tenderness.

Rest and serve: Let the chicken rest 5 minutes. Brush with a little extra warm sauce if you like. Serve with simple sides—slaw, corn, potato wedges, or a green salad.