Hearty Chili Mac Casserole with Melted Cheese

Quick Recipe Version (TL;DR)

• Yield: 6 to 8 servings
• Prep Time: 20 minutes
• Cook Time: 45 minutes
• Total Time: 1 hour 5 minutes

Quick Ingredients

• 12 oz elbow macaroni (or other short pasta)
• 1 tbsp kosher salt (for pasta water)
• 1 tbsp olive oil
• 1 medium yellow onion, diced
• 1 green bell pepper, diced
• 3 cloves garlic, minced
• 1 1/2 lb ground beef (80–90% lean)
• 2 tbsp chili powder, 1 tsp cumin, 1 tsp smoked paprika, 1/2 tsp oregano, 1/4 tsp cayenne (optional)
• 1 1/4 tsp kosher salt, 1/2 tsp black pepper
• 1 (15-oz) can tomato sauce
• 1 (14.5-oz) can diced tomatoes
• 1 (15-oz) can kidney beans, drained and rinsed
• 1 tsp brown sugar (optional)
• 2 cups (8 oz) shredded sharp cheddar cheese
• 1 cup (4 oz) shredded Monterey Jack or pepper Jack
• 2 green onions, sliced (optional garnish)

Do This

• 1. Preheat oven to 375°F (190°C). Grease a 9×13-inch baking dish or use a large oven-safe skillet.
• 2. Boil pasta in salted water until just shy of al dente (1–2 minutes less than package). Drain and set aside.
• 3. In a large skillet, sauté onion and bell pepper in olive oil until soft. Add garlic and cook briefly.
• 4. Add ground beef; cook until browned. Stir in spices, salt, and pepper. Cook 1–2 minutes.
• 5. Add tomato sauce, diced tomatoes, kidney beans, and brown sugar. Simmer 10–15 minutes, then stir in cooked pasta and half the cheese.
• 6. Transfer to baking dish (if needed), top with remaining cheese, and bake 20–25 minutes until bubbly and golden. Garnish with green onions and serve.

---

Why You’ll Love This Recipe

• It combines two classics—hearty beef chili and creamy macaroni and cheese—into one ultra-comforting bake.
• Everything cooks in just a couple of pans, then finishes in the oven for an easy, hands-off dinner.
• Flexible and family-friendly: mild enough for kids, easy to spice up for chili lovers.
• Perfect for leftovers, meal prep, potlucks, and cozy nights in.

Grocery List

• Produce: 1 medium yellow onion, 1 green bell pepper, 3 cloves garlic, 2 green onions, fresh cilantro or parsley (optional).
• Dairy: Sharp cheddar cheese, Monterey Jack or pepper Jack cheese, Parmesan cheese (optional), sour cream (optional).
• Pantry: Elbow macaroni (or similar pasta), olive oil, kosher salt, black pepper, chili powder, ground cumin, smoked paprika, dried oregano, cayenne pepper (optional), brown sugar (optional), 1 can tomato sauce, 1 can diced tomatoes, 1 can kidney beans, nonstick spray or a little extra oil for greasing the dish.

Full Ingredients

Pasta Base

• 12 oz elbow macaroni, cavatappi, or other short pasta
• 1 tbsp kosher salt (for the pasta cooking water)

Hearty Chili Layer

• 1 tbsp olive oil
• 1 medium yellow onion, diced (about 1 cup)
• 1 green bell pepper, diced (about 1 cup)
• 3 cloves garlic, minced
• 1 1/2 lb ground beef (80–90% lean)
• 2 tbsp chili powder
• 1 tsp ground cumin
• 1 tsp smoked paprika
• 1/2 tsp dried oregano
• 1/4 tsp cayenne pepper (optional, for heat)
• 1 1/4 tsp kosher salt, plus more to taste
• 1/2 tsp freshly ground black pepper
• 1 (15-oz) can tomato sauce
• 1 (14.5-oz) can diced tomatoes, with juices
• 1 (15-oz) can kidney beans, drained and rinsed
• 1 tsp brown sugar (optional, to balance acidity)

Cheesy Topping and Mix-Ins

• 2 cups (8 oz) shredded sharp cheddar cheese, divided
• 1 cup (4 oz) shredded Monterey Jack or pepper Jack cheese, divided if desired
• 1/4 cup finely grated Parmesan cheese (optional, for extra savory flavor)

Optional Garnishes

• 2 green onions, thinly sliced
• Sour cream
• Fresh cilantro or parsley, chopped
• Crushed tortilla chips or corn chips, for crunch

Step-by-Step Instructions

Step 1: Preheat the oven and prepare your baking dish

Preheat your oven to 375°F (190°C). Grease a 9×13-inch baking dish with a little olive oil or nonstick spray. If you have a large, deep, oven-safe skillet (such as a 12-inch cast iron skillet), you can cook the chili right in it and bake the casserole in the same pan for easier cleanup and a rustic presentation.

Step 2: Cook the pasta just shy of al dente

Bring a large pot of water to a rolling boil. Add 1 tbsp kosher salt to season the water. Add the 12 oz pasta and cook according to package directions, but stop 1–2 minutes before it reaches al dente. The pasta will continue to soften in the oven, so slightly undercooking keeps it from turning mushy.

Once the pasta is ready, drain it well in a colander. Toss it gently to release steam so it does not sit in water and overcook. Set aside while you prepare the chili layer.

Step 3: Sauté the aromatics for the chili base

While the pasta water is heating or the pasta is cooking, heat 1 tbsp olive oil in a large deep skillet or Dutch oven over medium heat. Add the diced onion and green bell pepper. Cook, stirring occasionally, for 5–7 minutes until softened and starting to turn golden at the edges.

Add the minced garlic and cook for another 30–60 seconds, stirring constantly, just until fragrant. Be careful not to let the garlic brown, as it can become bitter.

Step 4: Brown the ground beef and add spices

Add the 1 1/2 lb ground beef to the skillet with the vegetables. Use a wooden spoon or spatula to break the meat into small crumbles. Cook, stirring occasionally, for 6–8 minutes, until the beef is no longer pink and any excess moisture has mostly evaporated.

Sprinkle in the 2 tbsp chili powder, 1 tsp cumin, 1 tsp smoked paprika, 1/2 tsp dried oregano, and 1/4 tsp cayenne pepper (if using). Season with 1 1/4 tsp kosher salt and 1/2 tsp black pepper. Stir well to coat the beef and vegetables in the spices and cook for 1–2 minutes to toast the spices and deepen their flavor.

Step 5: Add tomatoes and beans, then simmer the chili

Pour in the tomato sauce and the can of diced tomatoes with their juices. Stir in the drained and rinsed kidney beans and the optional 1 tsp brown sugar if you prefer a slightly mellowed, less acidic sauce.

Bring the mixture to a gentle simmer, then reduce the heat to medium-low. Let the chili bubble softly for 10–15 minutes, stirring occasionally, until slightly thickened and flavorful. Taste and adjust seasoning with additional salt, pepper, or cayenne, if desired. You want a saucy chili that will coat the pasta but not be soupy.

Step 6: Combine the pasta, chili, and cheese

Turn off the heat under the chili. Add the cooked, drained pasta directly into the skillet or pot with the chili. Gently fold everything together until the pasta is well coated and evenly distributed.

Stir in about 1 cup of the shredded cheddar and 1/2 cup of the Monterey Jack, plus the optional 1/4 cup grated Parmesan if using. The residual heat will start to melt the cheese and bind the mixture together.

If you are not using an oven-safe skillet, transfer the chili-mac mixture to your prepared 9×13-inch baking dish, spreading it into an even layer. Sprinkle the remaining 1 cup cheddar and 1/2 cup Monterey Jack evenly over the top to form a generous cheesy blanket.

Step 7: Bake until bubbly and serve hot

Place the casserole into the preheated 375°F (190°C) oven. Bake, uncovered, for 20–25 minutes, or until the cheese is fully melted, the edges are bubbling, and the top has a few golden-brown spots.

Remove from the oven and let the chili mac casserole rest for 5–10 minutes to set slightly. This makes it easier to scoop and helps the flavors mingle. Top with sliced green onions and any other garnishes you like, such as a dollop of sour cream, a sprinkle of fresh cilantro or parsley, or a handful of crushed tortilla chips for crunch. Serve warm in hearty scoops.

Pro Tips

• Slightly undercook the pasta: Pull the pasta from the boiling water 1–2 minutes early. It will finish cooking in the oven and hold its shape better.
• Shred your own cheese: Pre-shredded cheese is convenient but often has anti-caking agents that prevent smooth melting. Freshly shredded blocks of cheddar and Jack melt more evenly and taste richer.
• Adjust the heat level: For very mild chili, skip the cayenne and cut back on the chili powder. For a spicier dish, add extra cayenne or a pinch of crushed red pepper.
• Use the right pan: A deep cast iron skillet or Dutch oven lets you go from stovetop to oven in one pan and gives a rustic, cozy look for serving at the table.
• Let it rest before serving: A short rest after baking helps the cheese set slightly and keeps the casserole from falling apart when you scoop it.

Variations

• Turkey or chicken chili mac: Swap the ground beef for ground turkey or chicken. Add an extra teaspoon of olive oil if using very lean meat so the chili does not dry out.
• Vegetarian chili mac: Omit the ground beef and add an extra can of beans (such as black beans or pinto beans) plus 1 cup of corn kernels. Use vegetable broth instead of any meat drippings if you thin the sauce.
• Spicy chipotle version: Add 1–2 minced chipotle peppers in adobo and 1 tablespoon of the adobo sauce to the chili in place of or in addition to the cayenne for smoky heat.

Storage & Make-Ahead

Let the casserole cool to room temperature before storing. Cover the baking dish tightly with foil or transfer leftovers to airtight containers. Refrigerate for up to 4 days. Reheat individual portions in the microwave until hot, or rewarm a larger portion in a 350°F (175°C) oven, covered with foil, for 20–25 minutes or until heated through.

To make ahead, assemble the casserole completely but do not bake. Cover tightly and refrigerate for up to 24 hours. When ready to bake, let it sit at room temperature for 20–30 minutes while the oven preheats, then bake at 375°F (190°C) for 25–30 minutes, until hot and bubbly. You can also freeze the fully assembled, unbaked casserole (tightly wrapped) for up to 3 months. Thaw overnight in the refrigerator before baking as directed, adding 5–10 minutes if needed.

Nutrition (per serving)

Approximate values for 1/6 of the recipe (using 85% lean ground beef and full amounts of cheese): about 650 calories, 35 g protein, 55 g carbohydrates, 30 g fat, 13 g saturated fat, 7 g fiber, and 1200 mg sodium. Actual values will vary based on brands, exact cheeses used, and any garnishes or variations.