If you are craving a hearty, flavorful pasta dish that combines a little heat with fresh, vibrant flavors, you are going to adore this Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe. It effortlessly marries spicy Italian sausage, tender zucchini, and rigatoni pasta with a rich, herby tomato sauce, all baked to bubbly perfection with layers of melted mozzarella and Parmesan. This recipe is a comfort food classic with a fresh twist that is perfect for feeding a crowd or enjoying leftovers all week long.
Ingredients You’ll Need
Keeping the ingredients simple yet carefully chosen is the key to nailing this dish. Each component plays an essential role in the beautiful balance of spice, freshness, and creaminess that makes this meal so irresistible.
- Uncooked rigatoni pasta: The ridged tubes hold onto the sauce beautifully, making every bite saucy and satisfying.
- Zucchini: Adds a fresh, slightly sweet crunch that contrasts wonderfully with the spicy sausage.
- Olive oil: For sautéing and bringing out the rich flavors of the vegetables and sausage.
- Italian sausage: The hearty, spicy meat backbone of this dish, delivering bold flavor and protein.
- Yellow onion: Adds sweetness and depth when sautéed to soft perfection.
- Garlic: Infuses the sauce with a fragrant and savory punch.
- Crushed red pepper flakes: For that signature Fra Diavolo heat that wakes up the palate.
- Tomato paste: Intensifies the tomato flavor and thickens the sauce.
- Crushed tomatoes with basil: The juicy base of the sauce, providing fresh, tangy sweetness balanced with herbaceous notes.
- White wine or chicken broth: Adds acidity and complexity to the sauce’s flavor profile.
- Fresh basil and mint: Bright, fresh herbs that add aroma and freshness, lifting the entire dish.
- Salt and black pepper: Essential seasonings that bring all the flavors together.
- Mozzarella cheese: The melty, gooey topping that creates an irresistible golden crust.
- Parmesan cheese: Adds a sharp, nutty finish as a perfect final touch.
How to Make Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe
Step 1: Prepare the Pasta
Start by preheating your oven to 350°F (175°C) and spritzing a 9×13-inch baking dish with nonstick spray to prevent sticking later on. Cook your rigatoni in salted boiling water for about 6 to 7 minutes until it is just al dente—firm but cooked through. Drain well and set the pasta aside, keeping it warm for later.
Step 2: Sauté the Zucchini
Heat a generous 1/4 cup of olive oil in a large skillet over medium heat. Add the chopped zucchini rounds and sauté until they turn golden and slightly caramelized, about 6 minutes. This step brings out their natural sweetness while adding a lovely texture. Once done, remove the zucchini and set it aside.
Step 3: Brown the Italian Sausage
In the same skillet, add the Italian sausage and cook for 5 to 7 minutes until nicely browned, breaking it up with your spatula as it cooks. Browning develops flavor and gives the sausage a satisfying texture. Then remove the sausage and keep it separate for now.
Step 4: Build the Sauce Base
Drain off any excess grease from the skillet, then add the remaining 1/4 cup olive oil. Toss in the diced yellow onion and cook until soft and translucent, about 8 minutes. Then, stir in the minced garlic and crushed red pepper flakes, letting them cook just a minute until fragrant—this subtle spicy garlic flavor forms the foundation of your sauce.
Step 5: Add Tomatoes and Herbs
Stir in the tomato paste, crushed tomatoes with basil, and your choice of white wine or chicken broth. Add the freshly sliced basil and roughly chopped mint for a fresh herbaceous lift. Season with salt and black pepper to taste. Let this sauce simmer gently so all the flavors meld into a beautiful, robust tomato base.
Step 6: Combine Sausage and Zucchini with Sauce
Return the cooked sausage and zucchini to the skillet, stirring them into the sauce to coat everything evenly. This step ensures every bite is loaded with mouthwatering savory bites and tender vegetables.
Step 7: Assemble and Bake
Pour the cooked rigatoni into your prepared baking dish, then ladle the saucy sausage and zucchini mixture evenly over the pasta. Sprinkle 1/2 of the mozzarella cheese over the top, then carefully toss everything together so the cheese starts to melt into the sauce. Top with the remaining mozzarella cubes for delightful cheesy pockets. Bake uncovered for 30 minutes or until the cheese is melted, golden, and bubbly.
How to Serve Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe
Garnishes
A sprinkle of finely grated Parmesan cheese right before serving adds a wonderful salty, nutty finish that complements the cheesy baked topping perfectly. Fresh basil leaves scattered on top bring a touch of herbal brightness and make the presentation pop.
Side Dishes
This dish pairs beautifully with a simple green salad tossed with a lemon vinaigrette or some roasted garlic bread to soak up any leftover sauce. If you want to keep it light, steamed green beans or a crisp arugula salad work magic alongside.
Creative Ways to Present
Serve the baked rigatoni family-style straight from the casserole dish for a rustic, cozy feel or portion it into individual ramekins for a charming dinner party presentation. For a festive touch, garnish with a few fresh mint leaves or a drizzle of high-quality olive oil right before serving.
Make Ahead and Storage
Storing Leftovers
Leftover Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe keeps well in an airtight container in the refrigerator for up to 4 days. The flavors tend to deepen over time, making leftover bites even more delicious.
Freezing
If you want to make this meal ahead in bulk, you can freeze the assembled (but unbaked) dish. Wrap well with plastic wrap and foil, then freeze for up to 3 months. When you’re ready, bake from frozen with a little extra time added, covered tightly to prevent drying.
Reheating
Reheat leftovers gently in the oven at 350°F until warmed through and bubbly, about 20 minutes, or microwave individual portions on medium power until hot. Be sure to cover while reheating to keep the cheese moist and melted perfectly.
FAQs
Can I use turkey sausage instead of Italian sausage?
Absolutely! Turkey sausage can be a leaner alternative and will still provide great flavor, just choose a variety with Italian seasoning or mild spices to keep that classic taste.
Is it necessary to use fresh herbs like basil and mint?
Fresh herbs definitely elevate this recipe by adding freshness and brightness, but if you only have dried, you can substitute a smaller amount—just reduce because dried herbs are more concentrated.
What if I don’t want spicy food? Can I skip the red pepper flakes?
Yes, you can omit the crushed red pepper flakes or reduce the amount for a milder dish. The sausage and herbs still provide plenty of flavor without the heat.
Can I make this recipe gluten-free?
Of course! Just swap regular rigatoni for a gluten-free pasta that holds up well to baking, such as corn or rice-based pasta, and follow all other instructions the same.
How can I tell when the pasta is perfectly al dente?
Al dente means the pasta is cooked until it is tender but still has a bit of bite in the center. Test by taking a piece out of the pot and biting into it; it should be firm yet easy to chew.
Final Thoughts
This Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe is truly a showstopper—packed with flavor, texture, and comforting warmth that will have everyone asking for seconds. Whether you’re cooking for family, friends, or just craving a delicious homemade meal, this dish strikes the perfect balance of spice, freshness, and indulgent cheesy goodness. I can’t wait for you to try it and make it a new favorite in your kitchen too!
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Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe
- Total Time: 50 minutes
- Yield: 8 servings 1x
Description
This Baked Rigatoni Fra Diavolo with Sausage and Zucchini is a hearty Italian-inspired dish featuring al dente rigatoni pasta baked with a spicy tomato sauce, flavorful Italian sausage, tender zucchini, and melty mozzarella cheese. The addition of fresh basil and mint leaves adds a refreshing herbal note, while the touch of crushed red pepper flakes brings just the right amount of heat. Perfect for a family dinner or entertaining guests, this recipe combines savory, spicy, and fresh flavors in a comforting baked pasta casserole.
Ingredients
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
Protein & Dairy
- 1 pound Italian sausage
- 1 pound part-skim mozzarella cheese (half shredded and half cut into 1-inch cubes)
- 1/2 cup Parmesan cheese, finely grated
Pasta & Pantry Items
- 1 pound uncooked rigatoni pasta
- 1/2 cup olive oil
- 1 teaspoon crushed red pepper flakes
- 2 tablespoons tomato paste
- 1 (28-ounce) can crushed tomatoes with basil
- 3/4 cup white wine or chicken broth
- 1 teaspoon salt
- 1/2 teaspoon black pepper
Instructions
- Preheat and prepare baking dish: Preheat your oven to 350°F (175°C). Lightly spray a 9×13-inch baking dish with nonstick cooking spray and set aside to use later.
- Cook pasta: Bring a large pot of salted water to a rolling boil. Add the rigatoni pasta and cook for 6 to 7 minutes until al dente. Drain the pasta and return it to the pot to keep warm.
- Sauté zucchini: In a large skillet, heat 1/4 cup of olive oil over medium heat. Add the chopped zucchini rounds and cook, stirring occasionally, until they are golden brown and tender, about 6 minutes. Remove from the skillet and set aside.
- Brown the sausage: Add the Italian sausage to the same skillet and cook over medium heat, breaking it apart with a spoon, until browned and cooked through, about 5 to 7 minutes. Remove the cooked sausage and set aside with the zucchini.
- Sauté onion and garlic: Drain any excess grease from the skillet. Add the remaining 1/4 cup olive oil and sauté the diced onion over medium heat until softened and translucent, approximately 8 minutes. Stir in the minced garlic and crushed red pepper flakes and cook for an additional 1 minute until fragrant.
- Make the sauce: Stir in the tomato paste until well combined. Add the crushed tomatoes with basil, white wine or chicken broth, fresh basil slices, fresh mint, salt, and black pepper. Mix thoroughly to combine all the flavors.
- Combine sausage and zucchini with sauce: Return the browned sausage and sautéed zucchini to the skillet with the tomato sauce. Stir to distribute evenly and heat through for a minute or two.
- Assemble and bake: Pour the cooked rigatoni pasta into the prepared baking dish. Top evenly with the mozzarella cheese, both shredded and cubed. Bake in the preheated oven for about 30 minutes, or until the cheese is melted, bubbly, and lightly golden.
- Serve: Remove from the oven and serve warm, sprinkled with the finely grated Parmesan cheese for extra richness and flavor.
Notes
- You can use either white wine or chicken broth depending on your preference or availability. The wine adds depth while broth keeps it lighter.
- For a spicier dish, increase the crushed red pepper flakes to taste.
- Part-skim mozzarella keeps the dish lighter, but whole milk mozzarella can be used for a richer flavor.
- Make sure not to overcook the pasta before baking to maintain a perfect al dente texture after baking.
- Fresh herbs like basil and mint brighten the sauce; feel free to adjust the amount or leave out the mint if preferred.
- Prep Time: 15 minutes
- Cook Time: 35 minutes
- Category: Main Dish
- Method: Baking
- Cuisine: Italian
