Name: Baked Rigatoni Fra Diavolo with Sausage and Zucchini
Prep time: 15 min
Cook time: 45 min
Total time: 1 h
Cuisine: Italian‑American
Ingredients: 1 pound uncooked rigatoni pasta; 2 large zucchini, chopped into ¼‑inch rounds; ½ cup olive oil, divided; 1 pound Italian sausage; ½ cup yellow onion, diced; 8 garlic cloves, minced; 1 teaspoon crushed red pepper flakes; 2 tablespoons tomato paste; 1 (28‑ounce) can crushed tomatoes with basil; ¾ cup white wine or chicken broth; ½ cup fresh basil leaves, thinly sliced; ¼ cup fresh mint leaves, roughly chopped; ¼ cup fresh parsley, roughly chopped; 1 teaspoon salt; ½ teaspoon black pepper; 1 pound mozzarella (½ shredded, ½ cut into 1‑inch cubes); ½ cup finely grated Parmesan cheese

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This baked rigatoni fra diavolo with sausage and zucchini is everything I love about Italian comfort food. It’s loaded with a spicy tomato sauce, fresh herbs, tender zucchini, and plenty of gooey mozzarella and Parmesan cheese. The perfect balance of heat, heartiness, and cheesy goodness makes it a go-to dinner when I want something both satisfying and vibrant. Baked Rigatoni Fra Diavolo with Sausage and Zucchini

Why You’ll Love This Recipe

I love how this dish brings together the best of several Italian classics—rigatoni, sausage and zucchini pasta, and spicy fra diavolo sauce—all baked into one bubbling casserole. The sauce has just the right amount of heat from crushed red pepper flakes, mellowed by the sweetness of tomatoes and freshness of basil, mint, and parsley. I also appreciate that it can be prepared ahead of time; I just assemble it, cover it with foil, and bake it when ready to serve.

Ingredients

(Here’s a tip: Check out the full list of ingredients and measurements in the recipe card below.)

1 pound uncooked rigatoni pasta
2 large zucchini, chopped into 1/4-inch rounds
1/2 cup olive oil, divided
1 pound Italian sausage
1/2 cup yellow onion, diced
8 cloves garlic, minced
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
1/2 cup fresh basil leaves, thinly sliced
1/4 cup fresh mint leaves, roughly chopped
1/4 cup fresh parsley, roughly chopped
1 teaspoon salt
1/2 teaspoon black pepper
1 pound mozzarella cheese, half shredded and half cut into 1-inch cubes
1/2 cup Parmesan cheese, finely grated

Directions

I preheat my oven to 350°F and spray a 9×13-inch baking dish with nonstick spray.
I bring a large pot of salted water to a boil.
In a skillet, I warm half the olive oil over medium-high heat and cook the zucchini until golden on both sides, about 6 minutes. I remove it and blot with paper towels to absorb excess moisture.
In the same skillet, I cook the sausage until browned, about 5–7 minutes, breaking it into small pieces. I transfer it to a plate and drain any extra grease.
I add the remaining oil to the pan with the onions, cooking until soft, about 8 minutes. Then I stir in garlic and red pepper flakes for one minute.
I mix in tomato paste, crushed tomatoes, and wine (or broth). I season with salt and pepper, letting it simmer for about 10 minutes before adding basil, mint, and parsley.
I stir the sausage and zucchini back into the sauce and remove from heat.
Meanwhile, I cook the rigatoni for only 6–7 minutes, so it stays very al dente. I drain it and mix it immediately with the sauce.
I pour everything into the prepared baking dish, topping it with both shredded and cubed mozzarella.
I bake it for 30 minutes, until the cheese is melted and bubbling. I serve it hot, sprinkled with Parmesan.

Servings and Timing

This recipe serves 8 people. It takes about 15 minutes of prep time and 45 minutes of cooking, for a total of 1 hour.

Variations

I sometimes swap the zucchini for mushrooms, bell peppers, or eggplant for a different texture.
If I want it extra spicy, I add more crushed red pepper flakes or a dash of chili oil.
For a lighter version, I use turkey sausage or even omit the meat for a vegetarian take.
I occasionally stir in ricotta cheese before baking for a creamy touch.
For extra flavor, I use fire-roasted crushed tomatoes instead of plain ones.

Storage/Reheating

I store leftovers in an airtight container in the refrigerator for up to 4 days. When reheating, I cover it with foil and warm it in a 350°F oven for about 20 minutes, or until heated through. I can also reheat individual portions in the microwave with a splash of water to keep it from drying out. This dish also freezes beautifully—up to 3 months—so I often bake one for now and save another for later.

FAQs

How spicy is this recipe?

It has a medium heat level from the crushed red pepper flakes, but I can easily adjust it by adding more or less depending on my taste.

Can I make this ahead of time?

Yes, I often assemble it in the morning, cover it with foil, and refrigerate it until dinnertime. Then I bake it directly from the fridge, adding 10 extra minutes to the bake time.

What can I use instead of white wine?

If I prefer not to use wine, I substitute it with chicken broth or even vegetable broth for a similar depth of flavor.

Can I use a different type of pasta?

Absolutely. Penne, ziti, or any short pasta shape that holds sauce well works perfectly in this recipe.

How do I keep the zucchini from getting soggy?

I always cook the zucchini separately and blot it dry before adding it to the sauce. This prevents excess moisture from watering down the dish.

Conclusion

This baked rigatoni fra diavolo with sausage and zucchini is one of my favorite comforting pasta dishes. I love how it combines spicy, herby, and cheesy flavors into one rich, satisfying meal. Whether I’m serving it for a cozy family dinner or making it ahead for guests, it never disappoints. Each bite captures the essence of homemade Italian cooking—warm, flavorful, and impossible to resist.