In a large skillet over medium heat, cook the breakfast sausage until browned and crumbly, about 8-10 minutes. Drain excess fat and set aside to cool slightly.
Grease a 9x13-inch baking dish with cooking spray or oil.
Layer half of the tortilla pieces in the bottom of the dish. Top with the cooked sausage, black beans, corn, bell pepper, and 1 cup of the shredded cheese. Add the remaining tortilla pieces on top.
In a large bowl, whisk together eggs, milk, chili powder, cumin, garlic powder, salt, and pepper until well combined and slightly frothy.
Pour the egg mixture evenly over the casserole, making sure to saturate all the tortillas. Press down gently with a spatula.
Cover with plastic wrap and refrigerate for at least 3 hours or overnight to let the flavors meld.
To freeze: Cover the refrigerated casserole tightly with plastic wrap and then aluminum foil. Freeze for up to 3 months. Thaw completely in the refrigerator overnight before baking.
To bake: Preheat oven to 350°F. Remove plastic wrap and cover with foil. Bake for 35 minutes, then remove foil, sprinkle with remaining 1 cup of cheese, and bake uncovered for 10-15 minutes until cheese is melted and bubbly.
Let stand for 5-10 minutes before cutting. Serve with your favorite toppings like salsa, sour cream, diced avocado, and fresh cilantro.