Grilled Mozzarella BBQ Chicken Sandwiches: A Juicy, Melty, Backyard Favorite
Grilled chicken sandwiches are a classic for good reason—they’re easy to make, endlessly customizable, and when done right, totally crave-worthy. This grilled mozzarella BBQ chicken sandwich brings together tender, smoky grilled chicken, tangy barbecue sauce, and melted mozzarella cheese between soft buns for the ultimate summer-inspired sandwich.
Perfect for backyard cookouts, weekend family meals, or even weeknight dinners, this sandwich has all the components of comfort food but still feels light and fresh. The barbecue sauce adds a sweet and tangy layer of flavor, while the mozzarella cheese provides a gooey, creamy contrast. Pile it all into a toasted bun with your favorite toppings, and you’ve got a handheld masterpiece that’s as satisfying as it is simple.
Whether you’re grilling on the patio, using a stovetop grill pan, or even baking the chicken in the oven, this sandwich delivers bold flavor with minimal effort. In this post, we’ll walk through every step, offer variations, and share serving tips to help you turn this into your next favorite meal.
Ingredients
2 boneless, skinless chicken breasts (halved lengthwise for 4 thinner cutlets)
1/2 cup BBQ sauce (use your favorite brand or homemade)
4 slices mozzarella cheese
4 sandwich buns (brioche, Kaiser, or hamburger buns work well)
1 tablespoon olive oil
Salt and pepper to taste
Optional Toppings
Sliced red onion
Fresh lettuce
Tomato slices
Pickles
Extra BBQ sauce
Mayonnaise or garlic aioli
Step-by-Step Instructions
Step 1: Prep the Chicken
Slice each chicken breast horizontally to create two thinner cutlets. This helps the chicken cook faster and more evenly. Season both sides with salt and pepper, then brush with a light coat of olive oil to prevent sticking on the grill.
Step 2: Preheat the Grill
Heat your grill to medium-high (about 400°F). If using a grill pan, preheat it over medium heat on the stovetop.
Step 3: Grill the Chicken
Place the chicken on the hot grill and cook for 4-5 minutes per side, or until the internal temperature reaches 165°F and grill marks form. In the last two minutes of cooking, brush the chicken with BBQ sauce on both sides.
Step 4: Add the Cheese
Once the BBQ sauce is set and slightly caramelized, place a slice of mozzarella cheese on each chicken cutlet. Close the lid or cover with foil to melt the cheese, about 1 minute.
Step 5: Toast the Buns
Lightly toast the sandwich buns on the grill or in a skillet for 1-2 minutes until golden and slightly crisp.
Step 6: Assemble the Sandwiches
Spread additional BBQ sauce or your favorite spread on the buns. Add the cheesy BBQ chicken, then top with lettuce, tomato, onion, or any extras you love. Cap it with the top bun and serve immediately.
Why This Recipe Works
Grilled chicken is lean, flavorful, and holds up well to bold sauces like BBQ
Mozzarella melts beautifully and complements the tangy BBQ without overpowering it
Thin chicken cutlets cook quickly, keeping this recipe weeknight-friendly
The sandwich format makes it easy to serve, eat, and share
Versatile toppings let you make it your own
Best BBQ Sauces to Use
Classic hickory-smoked BBQ sauce
Honey BBQ for sweetness
Spicy chipotle BBQ for a kick
Carolina mustard-based sauce for a tangy twist
Homemade sauce made with ketchup, brown sugar, apple cider vinegar, and spices
Serving Ideas
Serve with a side of French fries, sweet potato wedges, or a fresh salad
Pair with grilled corn on the cob or coleslaw
Offer with iced tea, lemonade, or a crisp lager
Add a fruit salad or pasta salad for a complete summer meal
Variations to Try
Spicy Grilled BBQ Chicken Sandwich
Use a spicy barbecue sauce and top the chicken with pepper jack cheese and jalapeño slices.
Hawaiian BBQ Chicken Sandwich
Add a grilled pineapple ring and swap mozzarella for Swiss cheese. The sweetness plays beautifully with BBQ sauce.
Buffalo Mozzarella Chicken Sandwich
Swap BBQ sauce for buffalo sauce and serve with ranch dressing, shredded lettuce, and tomato.
BBQ Chicken Club Sandwich
Add crispy bacon, avocado slices, and cheddar cheese for a rich and indulgent twist.
BBQ Chicken and Slaw Sandwich
Top the chicken with creamy coleslaw for a crunchy contrast and a Southern-style vibe.
Using Leftovers
Use leftover grilled BBQ chicken in wraps, salads, or quesadillas
Chop up extra chicken and serve over rice or pasta with more sauce
Make a BBQ chicken pizza with leftover ingredients
Make It a Meal Prep Winner
Grill extra chicken, store in airtight containers, and reheat with cheese for easy lunches
Toast buns fresh or use sandwich wraps for a low-carb option
Keep toppings prepped in the fridge for quick assembly
Nutrition Information (Approximate Per Sandwich)
Calories: 470
Protein: 35g
Fat: 18g
Carbohydrates: 38g
Fiber: 2g
Sugar: 8g
Sodium: 720mg
Tips for the Best Sandwich
Always grill the chicken over medium-high heat for best sear
Use fresh mozzarella or thick-cut deli slices for extra melt
Toast the buns to prevent sogginess and add texture
Let the chicken rest for a minute after grilling before assembling the sandwich
Brush on BBQ sauce toward the end of cooking to avoid burning
Storage and Reheating
Store leftover grilled chicken in the fridge for up to 3 days
Reheat in a covered skillet over medium heat or in the microwave
Do not assemble sandwiches ahead—store ingredients separately to maintain freshness
Frequently Asked Questions
Can I use chicken thighs instead of breasts?
Yes. Boneless, skinless chicken thighs work well and offer more moisture. Adjust cooking time accordingly.
Can I make this in the oven?
Yes. Bake chicken at 400°F for 20–25 minutes or until cooked through. Add BBQ sauce and cheese during the last 5 minutes.
What kind of cheese can I substitute?
Swiss, provolone, gouda, or even smoked cheddar all work beautifully.
Can I use store-bought rotisserie chicken?
Yes. Slice and heat the rotisserie chicken with BBQ sauce, then melt mozzarella on top before assembling.
Can I make this gluten-free?
Use gluten-free BBQ sauce and serve on gluten-free buns or lettuce wraps.
Grilled Sandwich Party Tips
Offer multiple toppings and sauces so guests can customize
Slice sandwiches in halves or quarters for sharing
Serve with dipping sauces like ranch, blue cheese, or spicy mayo
Add a bowl of kettle chips or a colorful veggie tray on the side
Create a buffet-style build-your-own sandwich bar
How to Make It Even Better
Marinate chicken for 30 minutes in a mix of olive oil, garlic, lemon juice, and a splash of BBQ sauce
Add caramelized onions for extra sweetness
Use brioche or pretzel buns for richer flavor
Grill over real charcoal for authentic smoky taste
Finish with a splash of vinegar or squeeze of lemon for contrast
Perfect for Any Occasion
Summer barbecues
Family dinners
Game day feasts
Picnics and tailgates
Lunchbox meals (wrap in foil for easy transport)
Conclusion
Grilled mozzarella BBQ chicken sandwiches are everything you want in a handheld meal—juicy, cheesy, smoky, and full of flavor. They’re easy to make, loved by everyone, and endlessly customizable to suit your tastes or the occasion. Whether you’re planning a summer party, a casual dinner, or just want to level up your sandwich game, this recipe is your new secret weapon.
Ready to turn up the heat and make your own? Fire up the grill, grab your ingredients, and create a mouthwatering masterpiece that will keep everyone coming back for more.