If you’re craving a pasta dish that has the perfect balance of heat, heartiness, and fresh garden flavors, you are absolutely going to love this Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe. It’s a delightful Italian-inspired casserole that combines tender rigatoni pasta, spicy sausage, and tender zucchini all smothered in a vibrant fra diavolo tomato sauce. Baked until bubbly with layers of gooey mozzarella and sharp Parmesan, this dish is a comforting crowd-pleaser that brings a fresh twist to classic baked pasta with every bite.
Ingredients You’ll Need
This Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe is built on simple, fresh ingredients that all play a crucial role in delivering bold flavors and a rich, satisfying texture. Each component—from the hearty Italian sausage and tender zucchini to the fragrant herbs and spicy tomato sauce—works together to create a dish that’s both vibrant and comforting.
- Rigatoni pasta: Its ridged tubes trap the sauce beautifully for maximum flavor in each bite.
- Zucchini: Adds a fresh, tender veggie element that balances the richness of the sausage.
- Olive oil: Provides a luscious base for sautéing and deepens all the flavors.
- Italian sausage: Brings savory, spicy meatiness that makes the dish hearty and filling.
- Yellow onion: Adds sweetness when sautéed, giving depth to the sauce.
- Garlic: A classic flavor booster with a warm, aromatic punch.
- Red pepper flakes: Deliver that signature fra diavolo spice and heat.
- Tomato paste and crushed tomatoes: Create a rich, thick, and tangy sauce base with fresh basil notes.
- White wine or chicken broth: Adds acidity and complexity to the sauce layers.
- Fresh basil and mint leaves: Elevate the dish with herbal brightness and freshness.
- Salt and black pepper: Essential for seasoning and highlighting all the other tastes.
- Mozzarella cheese: Half shredded, half cubed for gooey, melty texture throughout.
- Parmesan cheese: Sprinkled on top for a sharp, nutty finish.
How to Make Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe
Step 1: Prep and Preheat
Start by heating your oven to 350°F (175°C). Grab a generous 9×13-inch baking dish and give it a quick spray with nonstick cooking spray – this will stop all the cheesy pasta goodness from sticking later on. It’s a small prep step but makes cleanup so much easier!
Step 2: Cook the Rigatoni
Bring a large pot of well-salted water to a lively boil, then add your rigatoni. Cook for about 6 to 7 minutes until just al dente – you want it tender but still with a bit of bite to hold up in the oven. Drain the pasta and toss it back into the pot to keep it warm.
Step 3: Sauté the Zucchini
In a wide skillet, heat 1/4 cup of olive oil over medium heat. Add the zucchini rounds and cook them until golden brown on both sides, about 6 minutes total. This step caramelizes the zucchini, bringing out their natural sweetness. Once done, remove them and set aside.
Step 4: Brown the Sausage
Using the same skillet, add the Italian sausage and cook it until it’s beautifully browned and cooked through, about 5 to 7 minutes. Browning the meat gives it a rich, savory depth that will build the sauce’s flavor. Remove the sausage and set aside as well.
Step 5: Build the Sauce Base
Pour out any excess grease from the skillet for a leaner sauce, then add the remaining olive oil. Toss in the diced onion and sauté until soft and translucent, which should take about 8 minutes. Stir in the garlic and crushed red pepper flakes—cook for just a minute to release their wonderful aromas without burning.
Step 6: Add Tomatoes and Seasonings
Next, stir in the tomato paste followed by the crushed tomatoes with basil for that vibrant red sauce. Pour in the white wine or chicken broth to add depth and loosen up the sauce a bit. Season with fresh basil, mint, salt, and black pepper, giving everything a good stir. Let this simmer gently to marry all the flavors together.
Step 7: Combine Sausage and Zucchini with Sauce
Return the browned Italian sausage and golden zucchini to the skillet, mixing well to coat them fully with the spicy fra diavolo sauce. This blending of textures and flavors is what makes this baked rigatoni dish truly sing.
Step 8: Assemble and Bake
Pour the cooked rigatoni into your prepared baking dish. Pour the sausage, zucchini, and sauce mixture evenly over the pasta and mix gently to combine. Then, top everything with half of the shredded mozzarella and scatter the mozzarella cubes on top for a perfect cheese pull as it melts. Bake the dish for 30 minutes until the cheese is bubbling and delightfully golden.
Step 9: Serve with Parmesan
Once baked, take the dish out and sprinkle the top generously with Parmesan cheese. This final addition offers a savory, nutty contrast that is just irresistible. Serve the pasta warm and watch everyone dive in happily!
How to Serve Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe
Garnishes
For added flair and flavor, sprinkle fresh basil leaves over the top right before serving. A drizzle of high-quality extra virgin olive oil can also brighten the dish. If you want a spicy kick, add a pinch more crushed red pepper flakes on each plate.
Side Dishes
This hearty rigatoni pairs beautifully with simple sides like a crisp green salad dressed in lemon vinaigrette or roasted garlic bread to soak up every bit of sauce. Steamed or grilled vegetables work well too if you want to add more fresh elements to the table.
Creative Ways to Present
Serve this Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe family-style in the baking dish for a cozy, inviting look. Alternatively, plate individual servings topped with a sprinkle of Parmesan and a few fresh herb leaves for an elegant touch at dinner parties or special occasions.
Make Ahead and Storage
Storing Leftovers
If you happen to have leftovers, don’t fret—they store beautifully in an airtight container in the refrigerator for up to 3 days. The flavors intensify with time, making it perfect for next-day meals.
Freezing
This baked pasta freezes wonderfully. Just cover it tightly with plastic wrap and foil or store in a freezer-safe container. Freeze for up to 2 months. When you’re ready to enjoy, thaw overnight in the refrigerator before reheating.
Reheating
Reheat leftovers in the oven at 350°F for 15-20 minutes until warmed through and the cheese is melty again. If you’re short on time, microwave on medium power in short intervals, stirring in between for even heat distribution.
FAQs
Can I use ground beef instead of Italian sausage?
Absolutely! Ground beef or even ground turkey can be great substitutes. Just add some Italian seasoning to keep the robust flavor that sausage typically provides.
What if I don’t have white wine for the sauce?
No worries! Chicken broth is a perfect substitute and still adds that needed liquid and subtle flavor complexity to the sauce.
How spicy is this Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe?
The crushed red pepper flakes provide a nice moderate heat that you can adjust to your liking—use less if you prefer milder or more if you love extra spice.
Can I make this dish vegetarian?
Yes! Simply omit the sausage and boost the veggies—adding mushrooms or eggplant are excellent choices that keep the dish hearty and delicious.
Is it important to use fresh herbs?
Fresh basil and mint brighten this dish and add a fresh finish that dried herbs can’t quite match. If you don’t have fresh, dried herbs can work in a pinch but use sparingly to avoid overpowering the sauce.
Final Thoughts
There’s something truly special about a baked pasta that brings everyone together, and this Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe is a standout for that reason. With its comforting layers of pasta, spicy tomato sauce, fresh vegetables, and melty cheeses, it’s the kind of meal that feels like a warm hug on a plate. Give it a try and watch it become a new favorite on your dinner rotation—you’re going to want to make this one again and again!
Print
Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe
- Prep Time: 15 minutes
- Cook Time: 35 minutes
- Total Time: 50 minutes
- Yield: 8 servings
- Category: Main Course
- Method: Baking
- Cuisine: Italian-American
Description
This Baked Rigatoni Fra Diavolo with Sausage and Zucchini is a spicy, comforting Italian-American casserole featuring tender rigatoni pasta baked with a flavorful spicy tomato sauce, sautéed Italian sausage, golden zucchini rounds, fresh herbs, and a luscious blend of mozzarella and Parmesan cheese. Perfect for a family dinner, this dish balances heat with fresh basil and mint, creating a rich, hearty meal bursting with Mediterranean flavors.
Ingredients
Pasta
- 1 pound uncooked rigatoni pasta
Vegetables & Herbs
- 2 large zucchini, chopped into 1/4-inch rounds
- 1/2 cup yellow onion, diced
- 8 cloves garlic, minced
- 1/2 cup fresh basil leaves, thinly sliced
- 1/4 cup fresh mint leaves, roughly chopped
Meat
- 1 pound Italian sausage
Liquids & Sauces
- 1/2 cup olive oil
- 2 tablespoons tomato paste
- 1 (28-ounce) can crushed tomatoes with basil
- 3/4 cup white wine or chicken broth
Spices & Seasoning
- 1 teaspoon crushed red pepper flakes
- 1 teaspoon salt
- 1/2 teaspoon black pepper
Cheese
- 1 pound part-skim mozzarella cheese (half shredded and half cut into 1-inch cubes)
- 1/2 cup Parmesan cheese, finely grated
Instructions
- Preheat and Prepare Baking Dish: Preheat your oven to 350°F (175°C). Spray a 9×13-inch baking dish with nonstick cooking spray and set it aside to be ready for assembling the pasta later.
- Cook the Pasta: Bring a large pot of salted water to a boil. Add the rigatoni and cook for 6-7 minutes until just al dente. Drain the pasta well, then return it to the pot to keep warm.
- Sauté the Zucchini: Heat 1/4 cup of olive oil in a skillet over medium heat. Add the chopped zucchini rounds and cook until they are golden brown and tender, about 6 minutes. Remove the zucchini from the skillet and set aside.
- Brown the Sausage: In the same skillet, add the Italian sausage and cook over medium heat until browned and cooked through, approximately 5 to 7 minutes. Remove the sausage and set aside with the zucchini.
- Sauté Aromatics: Drain excess grease from the skillet, then add the remaining olive oil. Sauté the diced onion over medium heat until soft and translucent, about 8 minutes. Add the minced garlic and crushed red pepper flakes, cooking for an additional 1 minute until fragrant.
- Make the Sauce: Stir in the tomato paste, crushed tomatoes with basil, white wine (or chicken broth), sliced fresh basil, chopped mint leaves, salt, and black pepper. Let the sauce simmer gently to combine flavors.
- Combine Sausage and Zucchini: Add the cooked sausage and sautéed zucchini back into the tomato sauce. Stir thoroughly to ensure even distribution in the sauce.
- Assemble for Baking: Pour the cooked rigatoni pasta into the prepared baking dish. Pour the sausage and zucchini tomato sauce evenly over the pasta. Top with shredded mozzarella and distribute the mozzarella cubes evenly on top.
- Bake: Bake the assembled rigatoni at 350°F (175°C) for 30 minutes, or until the cheese is fully melted, bubbly, and slightly golden.
- Serve: Remove from the oven and sprinkle the grated Parmesan cheese over the top. Serve the baked rigatoni warm for best flavor and texture.
Notes
- You can substitute the Italian sausage with ground turkey or chicken for a leaner option.
- If you prefer less heat, reduce or omit the crushed red pepper flakes.
- Use gluten-free rigatoni to make this dish gluten-free.
- Let the baked pasta rest for about 5 minutes before serving to allow it to set.
- Leftovers refrigerate well and taste even better the next day.
