Cheesy Italian Sausage and Zucchini Stuffed Shells
If you’re looking for the ultimate cozy dinner, these Italian Sausage and Zucchini Stuffed Shells are pure comfort food. Tender jumbo pasta shells are filled with a creamy ricotta and zucchini mixture, smothered in a hearty Italian sausage tomato sauce, and baked with lots of gooey mozzarella and parmesan cheese on top. It’s a hearty, family-style meal that feels special but is easy enough for a weeknight.
This stuffed shells recipe is a perfect way to sneak in extra veggies without sacrificing flavor. The golden zucchini slices add sweetness and texture, while the sausage gives the dish that classic Italian flavor. It’s cheesy, saucy, and satisfying — everything a baked pasta dish should be!
Why You’ll Love This Cheesy Italian Sausage and Zucchini Stuffed Shells
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Cheesy & comforting – creamy ricotta filling + melty mozzarella + nutty parmesan = pasta perfection.
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Vegetable-packed – zucchini blends right into the filling, adding flavor and nutrition.
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Crowd-pleasing – a cozy casserole-style dish that’s great for family dinners or potlucks.
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Make-ahead friendly – assemble ahead of time and bake when ready to serve.
Ingredients You’ll Need For This Italian Sausage and Zucchini Stuffed Shells
Here’s everything you’ll need to make these stuffed shells:
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Jumbo pasta shells – large enough to hold plenty of filling.
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Italian sausage – adds savory flavor and protein. Use sweet or spicy sausage depending on your preference.
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Zucchini – thinly sliced and pan-fried until golden brown for the filling.
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Onion & garlic – the aromatic base of the sauce.
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Marinara sauce – choose a good-quality jarred sauce or homemade.
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Diced tomatoes – adds extra texture to the sauce.
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Ricotta cheese – creamy and light for the filling.
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Mozzarella & parmesan cheese – for that irresistible cheesy top.
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Egg – helps bind the ricotta mixture together.
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Seasonings – Italian seasoning, garlic powder, salt, and black pepper for flavor.
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Parsley – fresh parsley for garnish (optional but adds freshness).
Step-by-Step Instructions For Cheesy Italian Sausage and Zucchini Stuffed Shells
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Cook the shells – Boil until al dente, drain, and spread on a baking sheet to cool.
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Fry zucchini – Pan-fry zucchini slices in batches until lightly golden. Drain on paper towels.
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Cook sausage & aromatics – In the same pan, sauté onion and garlic, then add sausage and cook until browned. Stir in marinara, diced tomatoes, and seasonings. Simmer, then set aside.
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Make ricotta filling – Mix ricotta, mozzarella, parmesan, egg, and fried zucchini until well combined.
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Assemble – Spread a layer of meat sauce on the bottom of your baking dish. Stuff shells with filling and arrange in a single layer. Top with the rest of the sauce and sprinkle with more cheese.
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Bake – Bake at 350°F for 20–25 minutes until bubbly and golden. Garnish with parsley and serve!
Tips for Success
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Don’t overcook the shells. They’ll continue baking in the oven, so boil until just al dente.
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Work in batches for the zucchini. Overcrowding will cause them to steam instead of fry.
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Use freshly grated cheese. It melts creamier than pre-shredded cheese.
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Make it ahead. Assemble the stuffed shells up to a day in advance and refrigerate, then bake when ready.
Ingredient Substitutions
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Protein – Swap Italian sausage for ground beef, turkey, or chicken.
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Vegetables – Add spinach, mushrooms, or bell peppers to the filling or sauce.
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Cheese – Try cottage cheese instead of ricotta for a lighter option.
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Gluten-free – Use gluten-free jumbo shells if available.
Serving Suggestions
This dish is hearty enough to stand alone, but pairs perfectly with:
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A crisp green salad with balsamic vinaigrette
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Garlic bread or focaccia
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A glass of red wine
Storage & Reheating
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Fridge: Store leftovers in an airtight container for up to 4 days.
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Freezer: Assemble the stuffed shells (before baking), cover tightly, and freeze for up to 3 months. Thaw in the fridge overnight and bake as directed.
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Reheat: Warm individual portions in the microwave, or cover with foil and reheat in the oven at 350°F until heated through.
FAQ
Can I make this vegetarian?
Yes! Simply leave out the sausage and add more vegetables like mushrooms, spinach, or eggplant to the sauce.
Can I use store-bought marinara?
Absolutely. A good jarred marinara works perfectly here. Just choose one with minimal added sugar.
Cheesy Italian Sausage and Zucchini Stuffed Shells
Ingredients
Main Ingredients:
- 20 jumbo pasta shells
- 1/2 cup oil - for frying zucchini
- 1 lb Italian sausage
- 2 medium zucchini - thinly sliced
- 1 yellow onion - finely diced
- 2 cloves garlic - minced
- 24 oz Marinara sauce
- 1 14.5oz can diced tomatoes
- 1 tsp Italian seasoning
- 1 tsp garlic powder
- Salt & black pepper - to taste
- Chopped parsley - for garnish
Cheese Filling
- 1 ½ cups Ricotta Cheese
- 4 cups about 16 oz shredded Mozzarella cheese, divided
- 1 cup freshly grated parmesan cheese - divided
- 1 large egg
Instructions
Cook the pasta:
- Boil pasta shells according to package directions until al-dente. Drain and rinse under cold water, then lay them out on a baking sheet to cool so them don’t stick together.
Fry the zucchini:
- Heat 3/4 cup of oil in a large frying pan oven medium-high heat. Once hot, add zucchini slices (make sure the zucchini slices are not sticking to each other) to the pan and cook until they are lightly golden brown on the edges, stirring occasionally. Work in 2–3 batches if needed to avoid crowding. Remove to a paper towel–lined plate to drain excess oil.
Cook the aromatics and sausage:
- In the same pan with about 2 tablespoons of oil (you may need to remove or add oil to the pan), add diced onions and sauté for about 3 minutes. Stir in garlic and sauté for 30 seconds. Push to the side of the pan, then add sausage. Break it apart and cook until browned.
Make the sauce:
- Stir the sausage, onions, and garlic together. Season with Italian seasoning, garlic powder, salt, and pepper. Add marinara sauce and diced tomatoes, then bring to a simmer. Turn off the heat and set aside.
Prepare the filling:
- In a large bowl, combine ricotta, 2 cups of mozzarella cheese, ¾ cups of parmesan cheese, egg, and fried zucchini. Season with a little bit of salt and black pepper. Mix until well combined.
Assemble the shells:
- Spread 1 cup of sausage sauce into the bottom of a 9”x13” baking dish. Spread 1 cup of the sausage sauce evenly over the bottom of the baking dish. Stuff each shell with about 2 tablespoons of the cheese mixture and place them face-up in a single layer. Add any leftover filling into the gaps between shells.
Top with sauce and cheese:
- Spoon the remaining sausage sauce evenly over the shells. Sprinkle with the remaining mozzarella and parmesan on top.
Bake the pasta:
- Bake at 350F for 20-25 minutes. Garnish with chopped parsley, serve warm, & enjoy!