If you’re craving a dish that delivers bold flavors and satisfying comfort, then the Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe is exactly what you need to try. This hearty bake brings together spicy, savory sausage, tender zucchini, and a vibrant tomato sauce all layered with melty mozzarella and Parmesan cheese. It’s the kind of dinner that feels cozy and indulgent, yet fresh and bright thanks to the herbs and veggies. Whether you’re looking for a family-friendly meal or an impressive dish to share with friends, this recipe stands out with its perfect harmony of heat, texture, and rich Italian-American charm.
Ingredients You’ll Need
This recipe thrives on simple yet thoughtfully chosen ingredients that each play a key role in building complex layers of flavor and texture. From the spicy Italian sausage to the fresh herbs and creamy cheeses, every component contributes to making this plate irresistible.
- 1 pound uncooked rigatoni pasta: The large tubes hold sauce beautifully, making every bite saucy and satisfying.
- 2 large zucchini, chopped into 1/4-inch rounds: Adds a subtle crunch and fresh vegetable balance.
- 1/2 cup olive oil: For sautéing and enriching the sauce with silkiness.
- 1 pound Italian sausage: Provides hearty, spicy, savory flavor that defines the Fra Diavolo style.
- 1/2 cup yellow onion, diced: Offers sweetness and depth when caramelized.
- 8 cloves garlic, minced: Infuses the sauce with pungent warmth and classic Italian aroma.
- 1 teaspoon crushed red pepper flakes: Adds the signature kick that makes this Fra Diavolo special.
- 2 tablespoons tomato paste: Concentrates and thickens the sauce with rich tomato essence.
- 1 (28-ounce) can crushed tomatoes with basil: The base of the sauce, vibrant and fresh-tasting.
- 3/4 cup white wine or chicken broth: Brightens and deglazes the pan, enhancing complexity.
- 1/2 cup fresh basil leaves, thinly sliced: Lends fragrant herbal notes and a pop of green color.
- 1/4 cup fresh mint leaves, roughly chopped: A surprising twist that brings refreshing brightness.
- 1 teaspoon salt: Balances and elevates all the flavors.
- 1/2 teaspoon black pepper: Adds subtle background spice.
- 1 pound part-skim mozzarella cheese (half shredded and half cut into 1-inch cubes): Melts perfectly for creamy, gooey texture.
- 1/2 cup Parmesan cheese, finely grated: Topped on at the end for nutty sharpness.
How to Make Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe
Step 1: Prepare Your Oven and Pasta
Start by preheating your oven to 350°F (175°C). A warmly heated oven ensures that your bake will cook evenly and the cheese will develop its beautiful golden bubbling crust. Meanwhile, cook your rigatoni in plenty of salted boiling water just until al dente—this means it should still have a slight bite to hold up in the bake without becoming mushy.
Step 2: Sauté the Zucchini
In a skillet, heat a quarter cup of olive oil and sauté the zucchini rounds until they turn golden brown on the edges. This quick caramelization not only adds wonderful texture but also sweetens the zucchini’s natural flavor, providing a colorful contrast to the hearty sausage and spicy sauce.
Step 3: Brown the Sausage
Next, use the same skillet to cook the Italian sausage until every bite is nicely browned and bursting with spicy juice. Browning the sausage properly is essential to develop those deep umami notes that make your baked rigatoni sing.
Step 4: Build the Sauce
After removing excess grease, add the remaining olive oil and sweat your diced onions until soft and translucent. This slow cooking draws out sweetness that balances the dish. Stir in minced garlic and crushed red pepper flakes for heat and aroma, cooking just until fragrant. Then, enrich the pan with tomato paste before adding crushed tomatoes, your choice of white wine or broth, fresh basil, mint, salt, and black pepper. This sauce, simmered to meld the flavors, brings together spicy, sweet, and herbal layers that perfectly match the sausage and zucchini.
Step 5: Combine and Bake
Return the cooked sausage and zucchini to the sauce and stir to coat everything evenly. Pour the cooked rigatoni into your prepared baking dish, then generously layer half shredded mozzarella and the cubed mozzarella on top, ensuring creamy pockets of melted cheese throughout. Bake uncovered for about 30 minutes until the cheese is melted, bubbly, and lightly browned, signaling that it’s time to enjoy.
How to Serve Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe
Garnishes
Finish your baked rigatoni with a generous sprinkle of finely grated Parmesan cheese, which adds a nutty, salty crunch that complements the rich tomato sauce. A few extra fresh basil leaves scattered on top brighten each mouthful and add a lovely herbal fragrance.
Side Dishes
Serve this filling pasta bake alongside a crisp green salad or roasted vegetables for balance. Garlic bread or a crusty Italian loaf can soak up any leftover sauce, turning every bite into a complete and satisfying meal.
Creative Ways to Present
For a fun twist on the classic, serve individual portions in small oven-safe ramekins to impress guests with personal cheese-topped servings. Layering the sausage and zucchini beneath the rigatoni before topping with cheese creates a layered look that’s both rustic and elegant.
Make Ahead and Storage
Storing Leftovers
Any leftovers of this Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe store beautifully covered in the refrigerator for up to 3-4 days. The pasta will soak up more sauce and flavors, often tasting even better the next day.
Freezing
You can freeze the baked rigatoni in an airtight container for up to 2 months. Thaw it in the fridge overnight before reheating to preserve the texture and flavor without watering down the sauce.
Reheating
Reheat portions in the oven at 350°F (175°C) until warmed through to keep the cheese melty and the edges slightly crisp. Alternatively, use a microwave for a quicker option, but cover the dish to prevent drying out.
FAQs
Can I use a different type of pasta?
Absolutely! While rigatoni is ideal for holding the sauce, penne or ziti are great alternatives and work just as well for this bake.
Is it possible to make this recipe vegetarian?
Yes, swap the Italian sausage for plant-based sausage or sauté extra vegetables like mushrooms and eggplants, which still keep the dish hearty and flavorful.
Can I adjust the spice level?
Definitely. Reduce or omit the crushed red pepper flakes to tame the heat, or add more if you love an extra spicy kick in your Fra Diavolo.
What kind of sausage is best to use?
Italian sausage with fennel seeds works beautifully here, especially the spicy variety, as it complements the tomato sauce perfectly.
How do I prevent the pasta from getting soggy?
Be sure to cook the rigatoni just until al dente and drain well before mixing it with the sauce to avoid a mushy texture in the bake.
Final Thoughts
This Baked Rigatoni Fra Diavolo with Sausage and Zucchini Recipe is a rewarding dish that brings warmth, flavor, and a little spicy flair to your kitchen. It’s one of those meals that comforts and excites at once, perfect for cozy nights or sharing with loved ones. Give it a try—you’re going to love how the layers of sausage, veggies, tangy tomato sauce, and gooey cheese come together in every delicious forkful.
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
Description
This Baked Rigatoni Fra Diavolo with Sausage and Zucchini is a hearty Italian-inspired casserole combining al dente rigatoni pasta with a spicy tomato sauce, savory Italian sausage, tender sauteed zucchini, and a melty mozzarella cheese topping. Finished with fresh basil, mint, and Parmesan, this dish delivers rich flavors with a comforting baked finish perfect for family dinners or entertaining guests.
Ingredients
Pasta
- 1 pound uncooked rigatoni pasta
Vegetables
- 2 large zucchini, chopped into 1/4-inch rounds
- 1/2 cup yellow onion, diced
- 8 cloves garlic, minced
Meat
- 1 pound Italian sausage
Herbs and Spices
- 1 teaspoon crushed red pepper flakes
- 1/2 cup fresh basil leaves, thinly sliced
- 1/4 cup fresh mint leaves, roughly chopped
- 1 teaspoon salt
- 1/2 teaspoon black pepper
Liquids & Condiments
- 1/2 cup olive oil (divided)
- 2 tablespoons tomato paste
- 1 (28-ounce) can crushed tomatoes with basil
- 3/4 cup white wine or chicken broth
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 Oven and Prepare Dish: 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 Pasta: Bring a large pot of salted water to a boil. Add the rigatoni pasta and cook for 6-7 minutes until it is al dente. Drain the pasta and return it to the pot to keep warm.
- Cook Zucchini: Heat 1/4 cup of olive oil in a skillet over medium heat. Add the chopped zucchini and cook until golden brown, which should take about 6 minutes. Once cooked, remove the zucchini and set aside.
- Cook Sausage: In the same skillet, add the Italian sausage and cook until browned, approximately 5-7 minutes. Remove the sausage from the skillet and set aside.
- Sauté Aromatics: Drain any excess grease from the skillet. Add the remaining 1/4 cup olive oil, then add the diced onions. Sauté the onions until they are soft, about 8 minutes. Add minced garlic and crushed red pepper flakes, cooking for an additional minute until fragrant.
- Prepare Sauce: Stir in the tomato paste, crushed tomatoes with basil, white wine or chicken broth, fresh basil, fresh mint, salt, and black pepper. Combine all ingredients well and let the sauce come together with the seasonings.
- Combine Ingredients: Return the cooked sausage and zucchini to the sauce, stirring to combine all the ingredients evenly.
- Assemble and Bake: Pour the cooked rigatoni pasta into the prepared baking dish. Top the pasta evenly with half shredded and half cubed mozzarella cheese. Bake in the preheated oven for 30 minutes until the cheese is melted, bubbly, and golden on top.
- Serve: Remove from the oven and serve warm. Sprinkle finely grated Parmesan cheese over each serving for an added touch of flavor.
Notes
- You can substitute white wine with chicken broth or vegetable broth for a non-alcoholic version.
- Part-skim mozzarella helps reduce fat but retains great melting qualities.
- If you prefer less heat, reduce or omit the crushed red pepper flakes.
- Fresh herbs elevate the flavor, but dried can be used if necessary—use about one-third the quantity if substituting dried herbs.
- Make sure not to overcook the pasta in boiling water since it will continue cooking in the oven.
