Description
This Baked Rigatoni Fra Diavolo with Sausage and Zucchini is a hearty Italian-American casserole featuring al dente rigatoni pasta tossed in a spicy tomato sauce with savory Italian sausage and tender zucchini. Topped with a generous layer of melted mozzarella and Parmesan cheese, this comforting baked pasta dish combines bold flavors from fresh herbs, garlic, and crushed red pepper flakes for a satisfying meal perfect for family dinners or entertaining.
Ingredients
Pasta and Vegetables
- 1 pound uncooked rigatoni pasta
- 2 large zucchini, chopped into 1/4" rounds
- 1/2 cup olive oil, divided
Meat and Aromatics
- 1 pound Italian sausage
- 1/2 cup yellow onion, diced
- 8 cloves garlic, minced
- 1 teaspoon crushed red pepper flakes
Tomato Sauce
- 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
Herbs
- 1/2 cup fresh basil leaves, thinly sliced
- 1/4 cup fresh mint leaves, roughly chopped
- 1/4 cup fresh parsley, roughly chopped
Cheese
- 1 pound (16 ounces) part-skim mozzarella cheese, half shredded and half cut into 1" cubes
- 1/2 cup Parmesan cheese, finely grated
Instructions
- Preheat and Prepare Baking Dish: Preheat your oven to 350°F. Spray a 9×13-inch baking dish with nonstick cooking spray and set it aside for later use.
- Cook Zucchini: Heat 1/4 cup of olive oil in a skillet over medium-high heat. Add the chopped zucchini rounds and cook until golden brown on both sides, about 6 minutes. Remove with a slotted spatula and place the zucchini on a paper towel-lined plate. Cover with another paper towel to soak up excess moisture, then set aside.
- Cook Sausage: In the same skillet, add the Italian sausage, breaking it into small pieces with a wooden spoon. Cook until browned and no pink remains, approximately 5 to 7 minutes. Remove the sausage with a slotted spoon to a large plate and set aside.
- Sauté Onion and Garlic: Drain excess grease from the pan, then return it to the stove and reduce heat to medium. Add remaining olive oil, then the diced onion. Cook, stirring occasionally, until the onion is very soft and translucent, about 8 minutes. Add minced garlic and crushed red pepper flakes, cooking for 1 minute until fragrant.
- Make Sauce: Stir in tomato paste, breaking it up with your spoon. Add crushed tomatoes and white wine or chicken broth. Season with salt and pepper. Let the sauce simmer, stirring occasionally, for about 10 minutes. Stir in fresh basil, mint, and parsley, adjusting salt and pepper to taste. Finally, fold the cooked sausage and zucchini into the sauce and remove the pan from heat.
- Cook Pasta: Meanwhile, bring a large pot of salted water to a boil. Add rigatoni and cook for 6 to 7 minutes until very al dente. Drain the pasta and immediately return it to the pot. Combine the pasta with the prepared meat sauce, stirring well to coat every piece.
- Assemble and Bake: Transfer the pasta and sauce mixture into the prepared baking dish. Evenly sprinkle shredded and cubed mozzarella cheese on top. Bake in the preheated oven for 30 minutes or until the cheese is melted, bubbly, and golden around the edges.
- Serve: Remove from oven and serve warm, topped with finely grated Parmesan cheese for an extra layer of flavor.
Notes
- Use part-skim mozzarella for a perfect balance of meltiness without excessive greasiness.
- White wine adds depth to the sauce; chicken broth is a good non-alcoholic substitute.
- Cooking zucchini separately ensures it browns nicely and doesn’t release excess water in the casserole.
- Be careful not to overcook the pasta in boiling water since it will continue cooking in the oven.
- Adjust crushed red pepper flakes according to your preferred spice level.
- Leftovers can be refrigerated for up to 3 days and reheated in the oven or microwave.
- Prep Time: 25 minutes
- Cook Time: 45 minutes
- Category: Main Course
- Method: Baking
- Cuisine: Italian-American
