The flapper-nozzle pilot stage, whose performance can be deteriorated by the generated flow cavitation phenomenon, is a vital segment in achieving precise control of electrohydraulic servo-valves. Aiming to find out a reasonable flapper shape to reduce cavitation, this paper presents a numerical study of cavitation phenomenon in a flapper-nozzle pilot stage with different flapper shapes. A simple rectangular shape, carefully designed without disturbing the flow control characteristics of the pilot stage, is set as an innovative flapper shape in this work. Cavitation phenomena in the pilot stage are simulated for both of the traditionally used flapper shape and the innovative flapper shape at flow conditions with various nozzle inlet pressures, 1 MPa to 7 MPa. Then, systematic comparison of resulted cavitation phenomena for the two different flapper shapes is carried out. The results confirm that, for both flapper shapes, cavitation commonly occurs along the nozzle tip wall beyond stagnation region. The curved edge in traditionally used flapper shape is a massive contributor of cavitation in the pilot stage and the selected innovative shape shows a significant reduction of cavitation on its surface. From the flow structure, it is also noticeable that undesired transverse lateral force of sheded vortices is eliminated by using the innovative flapper shape. Meanwhile, the innovative flapper shape highlights the same effectiveness on the performance of flow control as the traditionally used flapper shape. Thus, a simple and effective flapper shape is proposed for cavitation reduction in the flapper-nozzle pilot stage of an electrohydraulic servo-valve. (C) 2013 Elsevier Ltd. All rights reserved.