Cheesy Chili Mac Casserole with Crunchy Topping

Why You’ll Love This Recipe

• Two favorites in one: hearty chili meets creamy mac and cheese.
• Kid-friendly mild spice that you can easily dial up or down.
• Crowd-pleasing casserole with a bubbly, cheesy center and a crunchy breadcrumb top.
• Make-ahead and freezer-friendly—perfect for game day or busy weeknights.

Grocery List

• Produce: 1 onion, 1 red bell pepper (optional), 3 garlic cloves, 2–3 scallions or small bunch parsley
• Dairy: Sharp cheddar (12 oz block), cream cheese (4 oz) or sour cream (1/2 cup), unsalted butter (2 tbsp)
• Pantry: Ground beef or turkey (1 lb), elbow macaroni (12 oz), crushed tomatoes (28 oz), tomato paste, kidney beans (15 oz), beef or chicken broth (1 cup), olive oil, panko (1 cup), chili powder, ground cumin, smoked paprika, dried oregano, kosher salt, black pepper, optional brown sugar

Full Ingredients

Chili Base

• 1 tbsp olive oil
• 1 lb ground beef (85–90% lean) or ground turkey
• 1 medium yellow onion, diced (about 1 cup)
• 1 red bell pepper, small dice (about 1 cup; optional but recommended)
• 3 garlic cloves, minced
• 2 tbsp chili powder (mild, American-style)
• 1.5 tsp ground cumin
• 1 tsp smoked paprika
• 1 tsp dried oregano
• 1.25 tsp kosher salt, plus more to taste
• 1/2 tsp black pepper
• 2 tbsp tomato paste
• 1 cup low-sodium beef or chicken broth
• 1 (28 oz) can crushed tomatoes
• 1 (15 oz) can kidney beans, drained and rinsed
• 1 tsp brown sugar (optional, balances acidity)
• Pinch cayenne or red pepper flakes (optional for heat)

Pasta & Cheese

• 12 oz elbow macaroni
• 2 tbsp kosher salt for pasta water
• 12 oz sharp cheddar, freshly shredded, divided (about 3 cups)
• 4 oz cream cheese, cut into small cubes (or 1/2 cup sour cream)

Crunchy Topping

• 1 cup panko breadcrumbs
• 2 tbsp unsalted butter, melted
• 1/2 tsp garlic powder
• 1/4 tsp kosher salt
• 1/4 tsp smoked paprika (optional, for color)

To Serve

• 2–3 scallions, thinly sliced, or 2 tbsp chopped parsley
• Hot sauce, to taste (optional)

Step-by-Step Instructions

Step 1: Preheat, boil water, and prep the pan

Heat the oven to 375°F. Grease a 9×13-inch baking dish (or a 12-inch oven-safe skillet) with a little butter or cooking spray. Bring a large pot of water (at least 4 quarts) to a boil for the pasta.

Step 2: Brown the meat and soften aromatics

Heat the olive oil in a wide, heavy skillet over medium-high heat. Add the ground beef or turkey and cook, breaking it into small crumbles, until no longer pink, 6–8 minutes. If there’s excess fat, spoon off most of it. Add the diced onion, bell pepper, and garlic. Cook, stirring, until the vegetables soften and the mixture smells fragrant, about 3 minutes.

Step 3: Build the chili and simmer

Sprinkle in the chili powder, cumin, smoked paprika, oregano, salt, and black pepper. Stir in the tomato paste and cook for 1 minute to toast the spices. Pour in the broth, then add the crushed tomatoes, kidney beans, and brown sugar (if using). Add a pinch of cayenne if you like heat. Bring to a simmer and cook uncovered, stirring occasionally, until slightly thickened and rich, 10–12 minutes. Taste and adjust seasoning.

Step 4: Cook the macaroni two minutes shy of al dente

When the water boils, add 2 tbsp kosher salt, then the macaroni. Cook 2 minutes less than package directions (usually 5–6 minutes). Drain well; do not rinse.

Step 5: Combine chili, pasta, and cheeses

Off the heat, fold the drained macaroni into the chili. Add 2 cups (8 oz) of the shredded cheddar and the cream cheese (or sour cream). Stir until the cheeses melt and the mixture is thick and saucy. Taste and adjust with more salt or a splash of broth if needed; it should be generously seasoned and slightly loose (it will thicken in the oven).

Step 6: Make the crunchy topping

In a small bowl, mix the panko, melted butter, garlic powder, kosher salt, and smoked paprika (if using) until evenly moistened.

Step 7: Assemble and bake

Spread the chili-mac into the prepared baking dish. Sprinkle the remaining 1 cup (4 oz) cheddar evenly over the top, then cover with the panko mixture. Bake at 375°F until the casserole is bubbling at the edges and the topping is deeply golden, 18–22 minutes. If needed, broil for 1–2 minutes for extra color—watch closely. Let rest 5–10 minutes, then garnish with scallions or parsley and serve.

Pro Tips

• Undercook the pasta by 2 minutes so it finishes perfectly in the oven without going mushy.
• Shred your own cheddar for the best melt—pre-shredded blends often contain anti-caking agents that inhibit melting.
• Adjust the chili thickness: if it’s too tight before mixing with pasta, add 2–3 tbsp broth; if too loose, simmer 2–3 minutes more.
• Use an oven-safe skillet to cook the chili, then mix in the pasta and bake right in the same pan for fewer dishes.
• For an extra-crispy top, scatter a few additional dry panko crumbs over the buttered topping before baking.

Variations

• Turkey Light: Use lean ground turkey and low-sodium broth; add a splash of Worcestershire for extra savoriness.
• Veggie Chili-Mac: Swap the meat for 8 oz finely chopped mushrooms plus 1 extra can of beans; sauté mushrooms until browned before adding aromatics.
• Spicy Chipotle: Stir 1–2 chopped chipotles in adobo into the chili for smoky heat; finish with pepper jack mixed into the cheddar.

Storage & Make-Ahead

Refrigerate leftovers in an airtight container for up to 4 days. Reheat covered at 350°F for 20–25 minutes (add a splash of broth or milk if needed) or microwave in portions until hot. To make ahead, assemble up to the breadcrumb step, cover, and refrigerate up to 24 hours; add the topping just before baking. To freeze, assemble without the topping, wrap tightly, and freeze up to 3 months. Thaw overnight in the fridge, add the topping, and bake at 375°F until hot and bubbling (25–35 minutes). From frozen, bake covered at 375°F for 45 minutes, then uncover, add topping, and bake 20–25 minutes more.

Nutrition (per serving)

Approximate: 630 calories; 32 g protein; 56 g carbohydrates; 32 g fat; 4 g fiber; 980 mg sodium. Nutrition will vary based on ingredients and brands.