First Step: Pasta Preparation Preheat your oven to 350°F (175°C). Bring a large pot of salted water to a boil and cook 1 pound of rigatoni pasta (or elbow macaroni) until just al dente, about 7-8 minutes according to package directions. Drain the pasta thoroughly and set aside, as this ensures your baked Mexican mac and cheese has perfectly tender noodles that won’t get mushy.

Second Step: Cooking the Sausage and Aromatics While the pasta is cooking, heat 1 tablespoon of olive oil in a large skillet over medium-high heat. Add 16 ounces of pork sausage and ½ chopped onion. Cook, breaking up the sausage and stirring occasionally until browned and the onion turns translucent. This mixture adds savory depth and moisture to your mac and cheese. For plant-based preferences, substitute the sausage with vegan sausage crumbles.

Third Step: Adding Flavorful Elements Just before the sausage mixture is fully cooked, stir in 1 ounce of taco seasoning and one can (4.5 ounces) of chopped green chiles, including the juice. Then add 16 ounces (1 cup) of salsa verde, stirring well to combine all the bold Mexican flavors that make this mac and cheese truly stand out.

Fourth Step: Combining Pasta and Sausage Mixture Into a large bowl, gently mix the cooked pasta with your sausage and salsa verde mixture. Be careful not to over-stir; you want to preserve some texture rather than making it mushy. This step distributes all the savory, spicy elements evenly throughout the dish.

Fifth Step: Layering and Adding Cheese Spray a 9×13-inch baking dish with nonstick spray or line it with foil. Spread half of the pasta mixture evenly across the bottom. Sprinkle half of the 16 ounces of shredded Mexican blend cheese over this layer. Then add the remaining pasta mixture, followed by the last half of the shredded cheese on top. This layering helps the cheese melt naturally into a creamy sauce during baking.

Sixth Step: Baking Cover the dish loosely with foil and bake in the preheated oven for 30-35 minutes until the cheese melts fully and bubbles. Remove the foil and optionally broil for 2-3 minutes to create a crispy, golden cheese crust on top. Keep an eye on it to prevent burning.

Final Step: Resting and Garnishing Let the baked Mexican mac and cheese rest for about 10 minutes after baking to set and cool slightly. Garnish with optional fresh toppings like diced tomatoes, cilantro, sour cream, or crushed tortilla chips for extra flavor and crunchy texture. Serve warm and enjoy the rich, creamy, and spicy cheesy goodness.