Cheesy Sausage Macaroni Casserole Recipe

A veggie-packed Sausage Macaroni Casserole where the pasta cooks right in the oven and the dish finishes with bubbling, melted mozzarella. This easy, one-pan-style bake combines savory chicken sausage, colorful peppers and mushrooms in a tomato-based sauce that hydrates uncooked elbow pasta while baking, saving you time and reducing dirty dishes.

Macaroni and Sausage Casserole

Baked pasta that doesn’t require pre-boiling the noodles is a dinner-time win. Instead of boiling macaroni on the stove, the pasta bakes in the sauce in the casserole dish and absorbs flavor as it cooks. The total oven time is roughly 50–55 minutes, but most of that is hands-off, so you can prep sides, relax, or get other tasks done while it bakes.

How to Make Sausage Macaroni Casserole

All the components start in one deep skillet: brown the sausage, cook the vegetables, then combine sausage and sauce. Spoon part of the mixture into a baking dish, add the uncooked pasta, top with remaining sauce and cheese, then bake until the pasta is tender and the cheese is melted and golden. See the printable recipe card below for full measurements.

1. Brown the raw sausage: In a large, deep nonstick skillet, cook the sausage over medium-high heat until no longer pink, breaking it up into small pieces. Transfer to a bowl and set aside.
2. Sauté the aromatics and peppers: Add a tablespoon of olive oil to the skillet, reduce heat to medium, then cook chopped onion, garlic and chopped bell peppers until softened, about 6–7 minutes.
3. Add mushrooms and tomatoes: Return the browned sausage to the pan along with sliced mushrooms, drained diced tomatoes, marinara sauce, water (or broth), Italian seasoning and salt.
4. Simmer: Bring the mixture to a boil, then lower to medium-low and simmer 10 minutes to meld flavors and soften vegetables. Taste and adjust seasoning as needed.
5. Assemble: Spoon enough of the sausage-vegetable mixture to cover the bottom of a 9 × 13-inch baking dish. Add the uncooked elbow pasta in an even layer, then pour the remaining sauce over the top so the dry pasta is completely submerged. Sprinkle shredded mozzarella evenly over the casserole.
6. Bake: Cover tightly with foil and bake at 350°F for 50–55 minutes. Remove from the oven and let stand, covered, for 15 minutes before serving to allow the pasta to finish absorbing liquid and the casserole to set.

Variations

• Different proteins: Swap chicken sausage for ground turkey, chicken, beef, or Italian sausage. For a lighter option, lean turkey or chicken work well.
• Vegetarian: Omit the sausage and add extra vegetables or plant-based crumbles.
• No mushrooms? Replace them with extra bell peppers, chopped carrots, celery, zucchini, or yellow squash. Add firmer vegetables like carrots and celery with the peppers; add squash and zucchini closer to when mushrooms would be added.
• Liquids: Use chicken broth instead of water for more savory depth, or bone broth for extra protein and richness.
• Herbs and heat: Use dried thyme, oregano or parsley if you don’t have Italian seasoning. Add crushed red pepper flakes or choose a spicy sausage for heat.
• Dairy-free: Omit the cheese or use a plant-based cheese alternative.
• Pasta shapes: Any short pasta—fusilli, farfalle, or orecchiette—works. Note that regular semolina pasta may cook a bit faster than whole wheat, so check doneness around 30–40 minutes.
• If using pre-cooked pasta: Omit the extra water and bake the assembled casserole for about 25 minutes until heated through and the cheese is melted.

Serving Suggestions

This hearty casserole is a complete meal with protein and vegetables. Pair it with a simple green salad, roasted broccoli, or wilted spinach for extra greens and contrast. The warm, cheesy top and tomato-sausage base make it a satisfying family dinner.

Meal Prep and Storage

• Make-ahead: You can assemble the casserole up to 24 hours in advance. Cover tightly with foil and refrigerate. When ready to bake, allow it to sit at room temperature while the oven preheats, then bake as directed.
• Refrigerate: Store leftovers in an airtight container for up to 4 days.
• Freeze: Cool completely, then portion into individual containers for lunches or freeze a whole casserole. Properly stored, it will keep for up to 3 months.
• Thawing and reheating: Thaw in the refrigerator overnight, then reheat in the oven at 350°F until warm, or microwave individual portions until heated through.
• Smaller batch: Halve the recipe to fit a 9 × 9-inch dish if you’re serving fewer people.

Sausage Macaroni Casserole — Recipe Card

Disclosure: This post was sponsored by a brand mentioned in the original recipe. The recipe and testing were created by the author, and only products used in the kitchen were promoted.