Easy baked penne and smoked sausage casserole

The scent of baked penne and smoked sausage casserole filling my home instantly transports me to childhood Sunday meals at Grandma’s table.

Something magical happens when those tube-shaped pasta pieces mingle with chunks of savory sausage, all hugged by gooey cheese and robust tomato sauce.

I’ve updated Grandma’s recipe with a few special touches learned through years of cooking for my family.

The rich smokiness of the sausage paired with perfectly cooked pasta delivers that irresistible texture combination everyone loves.

Ready in just 15 minutes of prep time, this simple yet satisfying dinner consistently earns those appreciative murmurs that signal a true family favorite.

Why You’ll Love This Baked Penne and Smoked Sausage Casserole

This baked penne casserole shines because it combines simplicity with tremendous flavor – the sauce develops rich depth as it bubbles in the oven, and the cheese forms that irresistible golden crust we all fight over.

If you’re a fan of hot and melty cheese, a meaty tomato sauce, and hearty pasta, this should definitely be added to your weeknight rotation!

It’s pretty much as simple as pasta night can get while still having a tasty flavor payoff. Top it with some fresh basil, and it’s chef’s kiss!

I’m so glad you’re here in my kitchen for this baked penne and smoked sausage casserole! If you’re wondering what to try next, peek at my Million Dollar Spaghetti and Baked Ravioli.

Ingredients for This Baked Penne and Smoked Sausage Casserole

• 16 oz penne pasta
• 1 lb Italian sausage or smoked sausage (mild works beautifully for family meals)
• 2 tablespoons olive oil
• 1/2 medium onion, diced (sweet onions like Vidalia work wonderfully)
• 4 cloves garlic, minced
• 1 teaspoon Italian seasoning
• ½ teaspoon red pepper flakes (optional, gives the sauce a slight warmth)
• 24 oz marinara sauce (use a jarred variety you love or make homemade)
• 1.5 cups shredded mozzarella cheese
• 1 cup freshly grated Parmesan cheese
• Fresh basil for garnish (adds a pop of freshness)
• Salt and pepper to taste

For the best flavor, choose Italian sausage with good seasoning – Johnsonville works wonderfully and adds richness to the entire dish.

The red pepper flakes don’t make it particularly spicy but add a nice warmth to the sauce. If you’re feeding little ones who prefer less heat, simply omit them and choose a mild sausage variety.

How to Make Baked Penne and Smoked Sausage Casserole

1. Preheat your oven to 375°F and move the rack to the top third of the oven.
2. Boil the pasta in salted water for 2 minutes less than the package directions indicate. This is crucial – be careful not to overcook the penne because it’ll cook more in the oven. Once done, drain it and add it directly to a 9×13 baking dish.
3. Meanwhile, cook the sausage and onion in a skillet over medium-high heat, stirring occasionally, until the sausage has browned (about 8-10 minutes). If there’s a lot of excess fat, spoon most of it out.
4. Stir in the garlic and cook for about a minute until fragrant.
5. Add in the marinara sauce and red pepper flakes and cook for a couple more minutes until it’s warmed through.
6. Pour the sausage mixture into the baking dish with the pasta. Season with salt and pepper to taste. Toss until everything is well coated, then smooth it out into an even layer.
7. Top with the cheeses – sprinkle the mozzarella first, followed by the Parmesan.
8. Bake uncovered for 15 minutes, then broil for a few minutes to brown the cheese (watch it carefully so it doesn’t burn).
9. Allow to rest for a few minutes before serving – this helps the casserole set up and makes it easier to portion.
10. Garnish with fresh basil if desired, and serve immediately.

When I make this for my family, I use a cast iron skillet for the sautéing steps – it gives the sausage such a nice brown color.

For the Parmesan, I highly suggest grating it freshly from a block with a Microplane zester – the flavor is so much better than pre-grated!

Can I use different pasta shapes?

Absolutely! While penne works beautifully because the sauce gets trapped inside the tubes, rigatoni, ziti, or even fusilli would work wonderfully too.

Just remember to slightly undercook whatever shape you choose since it will continue cooking in the oven.

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Some Tips for the Best Baked Penne and Smoked Sausage Casserole

The secret to amazing texture is slightly undercooking your pasta – it continues cooking in the oven, and this prevents mushy pasta syndrome!

For deeper flavor, try browning your sausage really well; those caramelized bits add incredible richness to the final dish.

This recipe is pretty flexible. You can swap the Italian sausage for ground beef or even ground turkey if needed.

The mozzarella can be replaced with cheddar or use a mixture of the two for a different flavor profile. If you like more heat, try hot Italian sausage instead of mild.

If making ahead, assemble everything but don’t bake – instead, cover tightly and refrigerate for up to 24 hours or freeze for up to 3 months.

When ready to cook from refrigerated, bake covered with foil at 350°F for 30-40 minutes until hot throughout, then broil for the last few minutes.

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How do I store leftovers?

Store any leftovers in the fridge for a few days, letting it cool down first. The flavors actually get even better on day two!

To reheat, the oven gives best results, but you could freeze leftovers in individual portions if desired (though the texture may change slightly due to the dairy).

Can I make this vegetarian?

Yes! Simply swap the sausage for a plant-based alternative, or use roasted vegetables like zucchini, eggplant, and mushrooms for a hearty vegetable version.

The smoky flavor can be mimicked with a touch of smoked paprika.

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Why is my casserole watery?

This typically happens when the pasta isn’t drained well enough or if your marinara sauce is particularly thin.

Make sure to drain the pasta thoroughly, and if your sauce seems watery, simmer it for a few extra minutes to reduce and thicken before assembling the casserole.

Can I add vegetables to this casserole?

Definitely! Spinach, mushrooms, zucchini, or even broccoli make wonderful additions. For leafy greens like spinach, simply stir them in raw when mixing the pasta and sauce.

For firmer vegetables, sauté them briefly with the onions.

My Serving Suggestions

This baked penne and smoked sausage casserole pairs perfectly with a crisp green salad – I love using my crave-worthy Italian dressing or making a Caesar salad with homemade dressing and easy Parmesan croutons.

In my home, we never skip garlic bread for sopping up every last bit of sauce! A big slice of extra cheesy garlic bread is practically mandatory for pasta night at our house.

Top this baked pasta with garden basil or chopped parsley for a pop of freshness. This hearty dish works wonderfully for potlucks since it transports easily and stays warm.

My absolute favorite way to enjoy it, though, is on a Sunday evening with my family gathered around the table, everyone going back for seconds.