The automotive industry is transitioning to Zonal-oriented Architectures (ZoA) for Software-Defined Vehicles (SDVs), enabling frequent over-the-air (OTA) updates for 100+ Electronic Control Units (ECUs). While OTA updates improve efficiency, they introduce safety-critical security risks. Current standards like Uptane and AUTOSAR Adaptive rely on Public-Key Infrastructure (PKI). However, PKI-based authentication creates bandwidth bottlenecks in in-vehicle and vehicle-to-cloud (V2I) communication as ECU density increases. It also risks exposing sensitive vehicle configurations and passenger privacy due to centralized architectures. Next-generation Zonal SDVs require decentralized, scalable authentication with data privacy. To address this, we propose zk-ScalHard, a hardware-rooted, privacy-preserving authentication protocol. We introduce a decentralized, hierarchical trust-promotion model utilizing Silicon Physical Unclonable Functions (PUFs) and two novel Zero-Knowledge Proof (ZKP) circuits: (1) Zonal Identity and Integrity (ZIDI) and (2) High-Performance Computing Aggregation (HPCA). These circuits employ multi-party computation (MPC) and recursive aggregation to achieve decentralization and scalability. The integration of ZKPs and PUFs ensures 100% vehicle-level data sovereignty. Benchmarked against Uptane, zk-ScalHard achieves constant O(1) communication and verification complexity, improving upon the linear O(n) complexity of current systems. Evaluation shows a 99.2% reduction in authentication bandwidth and a 99.9% reduction in the temporal attack surface. Our results demonstrate that zk-ScalHard provides a scalable, secure, and GDPR-compliant architecture for future Zonal SDVs.

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