Zucchini and Sausage Pasta Casserole Recipe

About

Hearty penne pasta tossed with browned Italian sausage, tender zucchini, and rich marinara sauce, then topped with bubbling golden mozzarella for a satisfying baked casserole.

1. 1

   Preheat the Oven

   preheat 10 min

   Position a rack in the center of the oven and preheat to 375°F. Allow at least 10 minutes for the oven to fully come to temperature before baking the casserole.

2. 2

   Boil the Pasta Water

   prep 10 min

   Fill a large pot with generously salted water and bring to a boil over high heat. This will take approximately 8–10 minutes; start it early so it is ready when needed.

3. 3

   Cook the Penne

   cook 10 min

   Add the penne to the boiling water and cook for 2 minutes less than the package directions (about 9–10 minutes), so the pasta is slightly underdone — it will finish cooking in the oven. Drain the pasta through a colander and set aside.

4. 4

   Brown the Sausage

   cook 7 min

   Heat the olive oil in a large skillet over medium-high heat. Add the sausage and cook, breaking it up with a wooden spoon, for 5–7 minutes until fully browned and no pink remains (internal temperature should reach 160°F). Use a slotted spoon to transfer the sausage to a plate, leaving about 1 tablespoon of drippings in the pan.

5. 5

   Sauté the Zucchini and Garlic

   cook 5 min

   Add the garlic to the same skillet over medium heat and cook for 30 seconds until fragrant. Add the zucchini, Italian seasoning, red pepper flakes, salt, and black pepper, and sauté for 4–5 minutes until the zucchini is just softened but still holds its shape.

6. 6

   Combine the Casserole Filling

   prep 3 min

   Return the cooked sausage to the skillet with the zucchini. Add the drained penne and pour the marinara sauce over everything, stirring well to coat all the pasta evenly. Stir in half of the shredded mozzarella (1 cup) so it melts into the filling.

7. 7

   Assemble the Casserole

   prep 2 min

   Transfer the pasta mixture into a 9x13 baking dish and spread it into an even layer. Sprinkle the remaining 1 cup of mozzarella and the Parmesan cheese evenly over the top.

8. 8

   Bake the Casserole

   cook 25 min

   Bake uncovered in the preheated 375°F oven for 20–25 minutes, until the cheese is fully melted, golden, and bubbling around the edges. The top should have visible golden-brown spots; if desired, broil on high for the final 2 minutes for extra color.

9. 9

   Rest the Casserole

   rest 5 min

   Remove the casserole from the oven and let it rest on a heatproof surface for 5 minutes. This allows the sauce to thicken slightly and makes the casserole easier to portion and serve.

10. 10

    Serve

    serve

    Scoop generous portions into shallow bowls or onto plates. Serve immediately, optionally garnished with extra Parmesan or fresh basil.