When you’re craving something cozy, cheesy, and satisfying, look no further than this Cheese, Potato and Smoked Sausage Casserole. It’s the kind of recipe that hits all the right notes—hearty, creamy, smoky, and packed with cheesy goodness.

This is classic American comfort food at its best, combining tender Russet potatoes, smoky sausage, and a luscious homemade cheese sauce baked to golden perfection. It’s ideal for busy weeknights, weekend potlucks, or feeding a hungry crowd with minimal fuss.

This casserole is also a flexible, pantry-friendly dish—you may already have the ingredients on hand. With a little prep, a touch of whisking, and a short bake, you’ll have a bubbling hot tray of satisfaction on your table.

🧡 Why You’ll Love This Recipe

Creamy and Hearty: Velveeta melts into a silky, indulgent sauce that clings to every potato.
Smoky Savory Goodness: Sautéed smoked sausage adds bold flavor and meaty bite.
Family-Friendly: Even picky eaters can’t resist this combo.
Make-Ahead Friendly: Assemble ahead and bake later!
Budget-Conscious: Uses affordable, accessible ingredients.

🛒 Ingredient Spotlight

Here’s what you’ll need to bring this casserole to life:

🥔 Main Components:

3 cups peeled, cubed Russet potatoes – Boil until just tender. Russets hold up well and absorb flavor beautifully.
1 lb smoked sausage – Thinly sliced. Kielbasa or Andouille also work well.
1/2 lb Velveeta cheese – Melts into a smooth, creamy cheese sauce.
1/2 cup shredded sharp cheddar cheese – Sprinkled on top for an extra layer of cheesiness.

🧈 For the Roux and Sauce:

4 tbsp butter
4 tbsp flour
2 cups half & half (or whole milk) – For a richer, creamy base.
Salt & pepper to taste
1/4 tsp smoked paprika – Adds a warm, subtly smoky note.

👨‍🍳 Step-by-Step Instructions

Let’s break it down so every step is easy and fuss-free.

🔥 Step 1: Cook the Sausage

In a large skillet, heat 1–2 tablespoons of olive oil over medium-low. Add the sliced smoked sausage and sauté, stirring occasionally, until golden brown on both sides. This browning enhances the flavor and gives a slight crisp texture.

Pro Tip: Let the sausage brown undisturbed for a minute or two before stirring to develop a nice crust.

🥔 Step 2: Boil the Potatoes

While the sausage cooks, peel and cube your Russet potatoes. Boil in salted water until just fork-tender—not mushy. Drain well.

You can boil the potatoes a day ahead and refrigerate to save time!

🍲 Step 3: Layer in a Casserole Dish

Lightly grease a 9×13″ baking dish with nonstick spray. Add the drained potatoes and sautéed sausage. Toss gently to combine without mashing the potatoes.

🧄 Step 4: Make the Cheese Sauce

Return the skillet to medium heat. Melt 4 tablespoons of butter, then whisk in 4 tablespoons of flour to form a roux. Cook for about 1 minute, whisking constantly to eliminate the raw flour taste.

Slowly pour in 2 cups of half & half, whisking constantly in small batches to prevent lumps. Continue to stir and cook until the mixture thickens (about 3–5 minutes).

Add the cubed Velveeta, smoked paprika, and season with salt and pepper. Stir occasionally until the cheese melts completely and the sauce is silky smooth.

🧀 Step 5: Assemble and Bake

Pour the cheese sauce evenly over the potato and sausage mixture in the casserole dish. Top with 1/2 cup shredded sharp cheddar cheese for a golden, bubbly crust.

Bake at 350°F (175°C) for 35–45 minutes, or until the casserole is bubbly, the top is golden, and the potatoes are fully tender.

Let it rest for 5 minutes before serving.

🍽️ Serving Suggestions

This casserole is a filling main dish, but it pairs wonderfully with:

Steamed green beans or broccoli
Simple garden salad with vinaigrette
Buttered dinner rolls or cornbread
Crisp pickles or coleslaw (for a Southern touch)

Add a few dashes of hot sauce or serve with sour cream for those who like a little zing.

🔁 Storage & Make-Ahead Tips

To Store: Cover leftovers and refrigerate for up to 4 days.
To Reheat: Bake at 325°F covered with foil until hot, or microwave individual portions.
To Freeze: Let cool completely, then wrap tightly in foil and freeze for up to 3 months. Thaw overnight and bake until heated through.

🧠 Expert Tips & Variations

Add or Swap	Why It Works
Green Peas or Broccoli Florets	Adds color and nutrition
Spicy Andouille Sausage	For a Cajun twist
Colby Jack or Pepper Jack Cheese	More complex cheese flavor
Yukon Gold Potatoes	For a slightly buttery texture
Breadcrumb Topping	Add crunch by topping with toasted panko

🤔 Frequently Asked Questions

Can I use shredded hash browns instead of fresh potatoes?
Yes! Use thawed shredded hash browns and skip the boiling step. Just ensure they’re not too wet before layering.

Is it okay to use milk instead of half & half?
Absolutely. Whole milk will work just fine, though half & half makes it creamier.

Can I make this ahead of time?
Yes! Assemble everything except the shredded cheese topping, cover, and refrigerate. Add the cheese just before baking.