If you’re craving a dish that brings together bold flavors, comforting textures, and a touch of Italian passion, you have to try the Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe. This recipe mingles spicy Fra Diavolo sauce, savory Italian sausage, tender zucchini rounds, and gooey mozzarella all baked to bubbly perfection. Each bite bursts with a delightful balance of heat, herbaceous freshness, and rich, cheesy goodness that turns any meal into a celebration. Whether you’re feeding a crowd or savoring leftovers, this baked pasta is a surefire crowd-pleaser that feels like an Italian kitchen hug.
Ingredients You’ll Need
This recipe comes to life with simple, thoughtfully chosen ingredients that each play a special role in flavor, texture, and color. From hearty rigatoni to fragrant fresh herbs, each element amplifies the dish’s irresistible appeal.
- Rigatoni pasta: The ridged tubes are perfect to hold the spicy Fra Diavolo sauce and melted cheese inside for maximum flavor per bite.
- Zucchini: Adds a subtle, fresh crunch and lightens the dish with vibrant green rounds that soak up the sauce beautifully.
- Olive oil: Essential for cooking veggies and sausage, adding richness and helping build layers of flavor.
- Italian sausage: Brings a savory, mildly spiced meatiness that grounds the bold tomato sauce.
- Yellow onion: Caramelizes gently to provide a sweet, savory base note.
- Garlic: Infuses the dish with pungent warmth.
- Crushed red pepper flakes: Adds the signature kick that defines Fra Diavolo.
- Tomato paste: Concentrates the tomato flavor and deepens the sauce’s richness.
- Crushed tomatoes with basil: Offers bright acidity and herbaceous undertones.
- White wine or chicken broth: Adds subtle complexity and moisture to the sauce.
- Fresh basil and mint: These herbs lift the dish with fresh, aromatic bursts and a hint of unexpected mintiness.
- Salt and black pepper: To season perfectly and balance all flavors.
- Mozzarella cheese: Half shredded for melty coverage and half cubed for gooey pockets of cheesy heaven.
- Parmesan cheese: A final grated sprinkle for a nutty, savory finish.
How to Make Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe
Step 1: Prepare Your Baking Dish
First things first, preheat your oven to 350°F (175°C) and give your favorite 9×13-inch baking dish a light spray of nonstick cooking spray. This will help your baked masterpiece release easily after all that delightful bubbling and browning.
Step 2: Cook the Rigatoni
Bring a large pot of salted water to a rolling boil, then add your rigatoni. Boil for about 6 to 7 minutes until they’re perfectly al dente — tender yet firm to the bite. Drain the pasta and return it to the pot, ready to mingle with the rest of the ingredients.
Step 3: Sauté the Zucchini
In a large skillet, heat 1/4 cup of olive oil over medium heat. Add the zucchini rounds and cook until they develop a gorgeous golden-brown sear, about 6 minutes. This step is key to bringing out their natural sweetness and getting just the right texture before combining with the sauce. Set aside once done.
Step 4: Brown the Sausage
Using the same skillet, toss in the Italian sausage and cook until it’s browned through and fragrant, about 5 to 7 minutes. Browning enhances flavor and gives that satisfying bite to the dish. Once cooked, transfer the sausage aside with the zucchini.
Step 5: Build the Flavor Base
Drain any excess grease from the skillet then add the remaining 1/4 cup olive oil. Sauté the diced yellow onion over medium heat until soft and translucent, about 8 minutes. Next, add the minced garlic and crushed red pepper flakes and cook for just a minute. This short sauté intensifies their aromas without burning anything.
Step 6: Create the Fra Diavolo Sauce
Stir in the tomato paste to caramelize slightly, then pour in the crushed tomatoes with basil, followed by the white wine or chicken broth. Add the sliced fresh basil, roughly chopped mint, salt, and pepper. Let this simmer gently while you prepare to combine everything, allowing the flavors to meld into that signature spicy, herby sauce.
Step 7: Combine Sausage and Zucchini with Sauce
Now is the moment to fold the browned sausage and tender zucchini into your sauce mix. This combination delivers a wonderful balance of spicy meatiness and fresh vegetable texture throughout the entire dish.
Step 8: Assemble and Bake
Pour the cooked rigatoni into your prepared baking dish and stir to coat evenly in the sauce mixture. Top generously with half shredded mozzarella and the other half cubed mozzarella to create pockets of creamy cheese throughout your pasta bake. Pop it into your preheated oven for about 30 minutes, until the cheese melts and bubbles with golden spots on top.
Step 9: Serve with Parmesan
Remove your masterpiece and sprinkle freshly grated Parmesan over the top. This adds a slightly salty, nutty note that complements the spicy sauce and hearty sausage perfectly. Serve warm and watch everyone’s eyes light up!
How to Serve Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe
Garnishes
Freshly torn basil or a sprinkle of chopped mint on top adds a fragrant, vibrant pop of color and flavor that perfectly contrasts the spicy richness of the dish. A light drizzle of good olive oil can also elevate the final presentation and taste.
Side Dishes
Since this dish is hearty and packed with flavor, lighter sides work wonderfully. Think a crisp green salad with lemon vinaigrette, garlic bread to soak up every last bit of the sauce, or even roasted seasonal veggies to add texture contrasts.
Creative Ways to Present
Consider baking the pasta in individual ramekins for a stunning personal touch or stacking layers in a clear casserole dish to showcase those beautiful layers of pasta, sauce, meat, veggies, and cheese. For a fun twist, try topping with panko breadcrumbs mixed with Parmesan for an ultra-crispy crust.
Make Ahead and Storage
Storing Leftovers
After enjoying your feast, simply cool leftover baked rigatoni to room temperature and transfer to an airtight container. Stored in the fridge, it will keep beautifully for up to 3 days, flavors melding even more as it rests.
Freezing
This Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe freezes exceptionally well. Portion it into freezer-safe containers or wrap tightly with foil and plastic wrap before freezing for up to 3 months. It’s perfect for quick dinners on busy nights.
Reheating
For best results, thaw frozen portions overnight in the fridge. Reheat gently in the oven at 350°F (175°C) until warmed through, about 20 minutes. You can also microwave leftovers covered at medium power, but the oven helps retain that baked texture and bubbling cheese magic.
FAQs
Can I use a different type of pasta for this Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe?
Absolutely. While rigatoni’s shape is ideal for holding sauce and cheese, penne or ziti work wonderfully too. Just choose a tubular pasta that can trap the sauce inside each bite for maximum flavor.
Is it possible to make this recipe vegetarian?
Yes! Simply swap out the sausage for plant-based sausage or sautéed mushrooms and bell peppers. The combination of zucchini and herbs will maintain a delicious and hearty texture even without meat.
How spicy is this dish? Can I adjust the heat?
The crushed red pepper flakes add a pleasant kick that’s not overwhelming but definitely noticeable. Feel free to use less or more depending on your heat preference, or omit entirely for a milder version.
Can I prepare any steps ahead of time to make dinner quicker?
Definitely. You can chop the vegetables, cook the pasta, and make the sauce ahead of time. When ready to eat, simply assemble, add the cheese, and bake. This makes weeknight dinners a breeze!
What wine pairs best with the Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe?
A medium-bodied red wine with moderate tannins, like Chianti or Sangiovese, complements the spicy tomato sauce and sausage perfectly. If you prefer white, go for a crisp Pinot Grigio or Sauvignon Blanc.
Final Thoughts
Sharing this Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe with you feels like handing over a little love from my kitchen to yours. Its harmonious blend of spicy sauce, tender sausage, fresh zucchini, and melty cheese makes it a recipe you’ll want to come back to time and time again. Give it a try on your next pasta night and savor the warmth and joy it brings to the table!
Print
Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe
- Prep Time: 20 minutes
- Cook Time: 30 minutes
- Total Time: 50 minutes
- Yield: 8 servings
- Category: Main Course
- Method: Baking
- Cuisine: Italian-American
Description
A hearty and flavorful baked rigatoni dish featuring spicy Fra Diavolo sauce with Italian sausage and tender zucchini, topped with melted mozzarella and Parmesan cheese. This comforting casserole combines pasta, vegetables, and a robust tomato sauce to create a classic Italian-American meal perfect for family dinners.
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 & Oils
- 1/2 cup olive oil (divided: 1/4 cup for zucchini, 1/4 cup for sautéing onion)
- 3/4 cup white wine or chicken broth
Tomato & Seasonings
- 1 teaspoon crushed red pepper flakes
- 2 tablespoons tomato paste
- 1 (28-ounce) can crushed tomatoes with basil
- 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 the Oven: Preheat your oven to 350°F (175°C). Lightly spray a 9×13-inch baking dish with nonstick cooking spray and set it aside for later use.
- Cook the Pasta: Bring a large pot of salted water to a boil. Add the rigatoni and cook for 6-7 minutes until it’s al dente. Drain the pasta and return it to the pot to keep warm.
- Sauté the Zucchini: In a skillet, heat 1/4 cup of olive oil over medium heat. Add the chopped zucchini rounds and cook until they turn golden brown, about 6 minutes. Remove the zucchini from the skillet and set aside.
- Cook the Sausage: In the same skillet, add the Italian sausage and cook it until it’s browned thoroughly, around 5-7 minutes. Remove the sausage from the skillet and set aside.
- Sauté the Onions and Garlic: Drain any excess grease from the skillet. Add the remaining 1/4 cup olive oil and sauté the diced onion until it becomes soft and translucent, about 8 minutes. Add the minced garlic and crushed red pepper flakes; cook for an additional 1 minute until fragrant.
- Make the Sauce: Stir in the tomato paste, crushed tomatoes, and your choice of white wine or chicken broth. Add the fresh sliced basil, chopped mint, salt, and black pepper. Let the sauce simmer gently to meld flavors.
- Combine Ingredients: Return the cooked sausage and zucchini to the skillet with the sauce, stirring to combine everything evenly.
- Assemble the Casserole: Pour the cooked rigatoni into the prepared baking dish. Top it evenly with half shredded and half cubed mozzarella cheese.
- Bake: Place the baking dish in the preheated oven and bake for 30 minutes, until the cheese is melted, bubbling, and slightly golden.
- Serve: Remove from oven and sprinkle the dish with finely grated Parmesan cheese. Serve warm and enjoy your rich and comforting baked rigatoni Fra Diavolo.
Notes
- You can substitute chicken broth for white wine to keep the sauce alcohol-free.
- For a spicier dish, increase the crushed red pepper flakes to 1.5 teaspoons.
- To save time, the sausage can be cooked in advance and refrigerated until ready to use.
- Use part-skim mozzarella to reduce fat content without sacrificing melt quality.
- Make sure to salt the pasta water well; it should taste like the sea to enhance the pasta’s flavor.
- This dish can be prepared a day ahead and baked just before serving for convenience.
