A cheesy, protein-rich pasta bake layered with savory Italian sausage, rich tomato sauce, and melty mozzarella. Quick to prepare, full of flavor, and perfect for family dinners or meal prep.
1 large skillet or 4-quart Dutch oven (for cooking sausage and sauce)
1 Colander (for draining pasta)
1 9x13-inch casserole pan (for baking)
1 spatula or wooden spoon (for stirring)
Measuring cups and spoons
Ingredients
1pound454 g penne pasta
2tablespoonsolive oil
1pound454 g Italian sausage
1cuponionfinely chopped
1tablespoongarlicminced
4cupstomato sauce
1tablespoonItalian seasoning
1cupParmesan cheesefreshly grated, divided
¼cupfresh parsleyfinely chopped
¼cupfresh basilchopped
1teaspoonsaltor to taste
½teaspoonground black pepperor to taste
3cupsmozzarella cheeseshredded
Instructions
Preheat the Oven: Start by setting your oven to 375°F (190°C). Preheating is crucial because it ensures the casserole cooks evenly and the cheese melts to a perfect golden-brown crust. Place the oven rack in the center to allow even heat distribution. By the time your pasta and sauce are ready, the oven will be at the ideal temperature for baking a bubbly, cheesy dish.
Boil the Pasta: Fill a large pot with enough water to comfortably hold 1 pound (454 g) of penne pasta. Add a generous pinch of salt, which seasons the pasta from within as it cooks. Bring the water to a rolling boil over medium-high heat. add the pasta, stirring occasionally to prevent it from sticking together. Cook until al dente—tender but slightly firm to the bite—typically 8–10 minutes. Drain the pasta in a colander, leaving the starch intact to help the sauce cling. Set aside.
Cook the Sausage: While the pasta cooks, heat 2 tablespoons of olive oil in a large skillet or 4-quart Dutch oven over medium-high heat for about 2 minutes until the oil shimmers. Add 1 pound of Italian sausage, breaking it into small, bite-sized pieces with a spatula. Cook for 5–7 minutes, stirring occasionally, until browned evenly. Browning the sausage develops a deep, savory flavor that becomes the foundation of the sauce.
Sauté the Aromatics: Once the sausage is browned, add 1 cup of finely chopped onions and 1 tablespoon of minced garlic. Stir continuously for 2–3 minutes until the onions are translucent and soft, and the garlic releases its fragrant aroma. This step forms the flavorful base for the sauce, ensuring that every bite of pasta is infused with savory richness.
Simmer the Sauce: Pour 4 cups of tomato sauce into the skillet, stirring to combine with the sausage and aromatics. Reduce the heat to medium and add 1 tablespoon of Italian seasoning, ½ cup of freshly grated Parmesan, ¼ cup finely chopped parsley, and ¼ cup chopped basil. Season with 1 teaspoon salt and ½ teaspoon black pepper, adjusting to taste. Lower the heat and let the sauce simmer gently for 5–7 minutes, stirring occasionally. This allows the flavors to meld together, creating a rich, aromatic sauce.
Combine Pasta and Sauce: Add the drained pasta to the sauce, gently folding it in with a spatula until every piece is coated evenly. Take care to distribute the sausage and herbs throughout the pasta, so each bite is balanced and flavorful. This step ensures the pasta absorbs the sauce, making it rich and satisfying.
Layer the Casserole: Prepare a 9x13-inch casserole pan. Spread half of the pasta mixture evenly at the bottom. Sprinkle 1.5 cups of shredded mozzarella over this layer. Next, add the remaining pasta on top, followed by the remaining 1.5 cups of mozzarella and ½ cup Parmesan sprinkled evenly across the surface. Layering in this way creates pockets of gooey cheese and a beautifully golden crust on top.
Bake the Pasta: Place the casserole in the preheated oven and bake for 25 minutes. The cheese should melt completely, bubble, and turn golden brown. The aroma of Italian herbs, sausage, and melted cheese will fill the kitchen. Baking not only finishes the cooking process but also allows the flavors to develop fully, creating a comforting, hearty dish.
Rest the Pasta: Carefully remove the casserole from the oven and allow it to rest for 15 minutes before serving. This brief cooling period lets the pasta set, making it easier to serve without falling apart. The flavors continue to meld during this time, enhancing the richness of the sauce and the overall taste.
Serve and Enjoy: Scoop generous portions onto plates, ensuring each serving includes layers of pasta, sausage, and melted cheese. Garnish with additional chopped parsley or basil if desired. Serve hot and enjoy a protein-packed, fiber-rich, and comforting meal that’s perfect for family dinners, meal prep, or casual weeknight feasts.
Notes
You can swap Italian sausage for ground beef, turkey, or chicken if you prefer a milder flavor or leaner meat.
For a vegetarian version, use plant-based sausage or roasted vegetables like mushrooms, zucchini, or bell peppers.
Cooking pasta slightly under al dente is recommended since it will bake further in the oven and absorb the sauce.
Fresh herbs like basil and parsley add brightness, but dried herbs can be used in a pinch (reduce quantity by half).
Adjust the amount of cheese based on preference: add more mozzarella for extra gooeyness or sprinkle less for a lighter dish.
Simmering the sauce for a few extra minutes enhances the flavor, allowing the sausage, herbs, and tomato sauce to meld perfectly.
This recipe works well for meal prep: it can be made ahead, refrigerated, and baked just before serving.