Quick Recipe Version (TL;DR)
Quick Ingredients
- 1 lb (450 g) elbow macaroni
- 1 tbsp olive oil
- 1 1/2 lb (680 g) ground beef
- 1 medium onion, 1 green bell pepper, 3 cloves garlic
- Chili spices: 2 tbsp chili powder, 2 tsp cumin, 1 1/2 tsp smoked paprika, 1 tsp oregano, salt, pepper, pinch chipotle or cayenne
- 1 (15 oz) can tomato sauce, 1 (14.5 oz) can diced tomatoes, 1 (15 oz) can kidney beans, 1/2 cup beef broth
- 4 tbsp butter, 1/4 cup flour, 3 cups whole milk
- 4 1/2 cups shredded cheese total (3 cups sharp cheddar, 1 1/2 cups Monterey Jack or pepper Jack)
- 2 oz cream cheese (optional), 1 tsp Dijon, garlic & onion powder, extra smoked paprika
- Fresh cilantro or parsley, sliced green onions (for garnish)
Do This
- 1. Preheat oven to 375°F (190°C). Grease a 9×13-inch baking dish. Boil macaroni in salted water until just shy of al dente; drain.
- 2. Brown beef in olive oil over medium-high heat. Add onion, bell pepper, and garlic; cook until softened.
- 3. Stir in chili powder, cumin, smoked paprika, oregano, salt, pepper, tomatoes, tomato sauce, beans, and broth. Simmer 10–15 minutes until thickened.
- 4. In another pot, melt butter. Whisk in flour 1 minute, then slowly whisk in warm milk. Simmer until thick. Season with Dijon, garlic powder, onion powder, smoked paprika, and salt.
- 5. Off heat, stir 2 cups cheddar, 1 cup Monterey Jack, and cream cheese into the sauce until smooth.
- 6. In a large bowl or pot, combine cooked macaroni, chili, and cheese sauce. Spread into baking dish. Top with remaining cheeses.
- 7. Bake 15–20 minutes until bubbly and golden at edges. Rest 5–10 minutes, garnish with herbs, and serve.
Why You’ll Love This Recipe
- Two comfort food favorites in one: hearty smoky chili and ultra-creamy mac and cheese.
- Perfect for feeding a crowd, potlucks, game day, or a cozy family dinner.
- Make-ahead friendly and reheats beautifully for leftovers all week.
- Easy to customize with your favorite cheeses, spice level, and toppings.
Grocery List
- Produce: 1 medium yellow onion, 1 green bell pepper, 3 cloves garlic, fresh cilantro or parsley, green onions (optional), jalapeño (optional)
- Dairy: Whole milk, unsalted butter, sharp cheddar cheese, Monterey Jack or pepper Jack cheese, cream cheese (optional)
- Pantry: Elbow macaroni, olive oil, all-purpose flour, tomato sauce, diced tomatoes, kidney beans, beef broth (or bouillon), chili powder, ground cumin, smoked paprika, chipotle chili powder or cayenne, dried oregano, garlic powder, onion powder, Dijon mustard, kosher salt, black pepper, nonstick spray or extra oil for greasing
Full Ingredients
For the Pasta
- 1 lb (450 g) elbow macaroni
- 4 quarts water (for boiling pasta)
- 2 tbsp kosher salt (for salting the pasta water)
For the Smoky Ground Beef Chili
- 1 tbsp olive oil
- 1 1/2 lb (680 g) ground beef (80–90% lean)
- 1 medium yellow onion, finely diced (about 1 1/2 cups)
- 1 green bell pepper, finely diced (about 1 cup)
- 3 cloves garlic, minced
- 2 tbsp chili powder
- 2 tsp ground cumin
- 1 1/2 tsp smoked paprika, divided (1 tsp for chili, 1/2 tsp for cheese sauce)
- 1 tsp dried oregano
- 1/4–1/2 tsp chipotle chili powder or 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 / 425 g) can tomato sauce
- 1 (14.5 oz / 411 g) can diced tomatoes, with juices
- 1 (15 oz / 425 g) can kidney beans, drained and rinsed
- 1/2 cup (120 ml) low-sodium beef broth or water
For the Ultra-Cheesy Sauce & Casserole
- 4 tbsp (1/2 stick / 56 g) unsalted butter
- 1/4 cup (30 g) all-purpose flour
- 3 cups (720 ml) whole milk, warmed
- 1 tsp Dijon mustard
- 1/2 tsp garlic powder
- 1/2 tsp onion powder
- 1/2 tsp smoked paprika
- 3/4 tsp kosher salt (or to taste)
- 3 cups (about 12 oz / 340 g) shredded sharp cheddar cheese, divided (2 cups for sauce, 1 cup for topping)
- 1 1/2 cups (about 6 oz / 170 g) shredded Monterey Jack or pepper Jack cheese, divided (1 cup for sauce, 1/2 cup for topping)
- 2 oz (55 g) cream cheese, cut into small cubes and softened (optional, for extra creaminess)
For Serving (Optional but Recommended)
- 2 tbsp chopped fresh cilantro or flat-leaf parsley
- 2 tbsp thinly sliced green onions
- Thinly sliced or pickled jalapeños
- Sour cream or Greek yogurt, for dolloping
Step-by-Step Instructions
Step 1: Preheat the Oven and Prepare the Dish
Set an oven rack in the center position and preheat your oven to 375°F (190°C). Lightly grease a 9×13-inch (about 23×33 cm) baking dish with nonstick spray, butter, or a thin film of oil. This helps keep the chili mac from sticking and makes serving neater slices easier.
At the same time, fill a large pot with about 4 quarts of water and bring it to a boil over high heat. This will be for cooking the macaroni in the next step.
Step 2: Cook the Macaroni
Once the water is boiling, add 2 tablespoons of kosher salt to season it generously. Add the elbow macaroni and cook according to package directions, but reduce the cooking time by 1–2 minutes so the pasta is just shy of al dente. It will finish cooking in the oven, and slightly undercooking now helps prevent mushy noodles later.
When done, drain the pasta in a colander. Do not rinse; the starch on the noodles helps the sauce cling. Set aside while you make the chili and cheese sauce.
Step 3: Brown the Beef and Aromatics
While the pasta cooks, heat 1 tablespoon of olive oil in a large, deep skillet or Dutch oven over medium-high heat. Add the ground beef and break it into small crumbles with a wooden spoon or spatula. Cook for 5–7 minutes, stirring occasionally, until the beef is no longer pink and beginning to brown. If there is a lot of excess fat, spoon off some, leaving about 1–2 tablespoons in the pan.
Add the diced onion and bell pepper to the pan with the beef. Cook, stirring often, for 4–5 minutes, until the vegetables are softened and translucent around the edges. Stir in the minced garlic and cook for 30–60 seconds, just until fragrant.
Step 4: Build the Smoky Chili
Reduce the heat to medium. Sprinkle the chili powder, ground cumin, 1 teaspoon smoked paprika, dried oregano, chipotle or cayenne (if using), 1 1/4 teaspoons salt, and 1/2 teaspoon black pepper over the beef mixture. Stir well so the spices coat the meat and vegetables, and cook for about 1 minute to lightly toast the spices and bring out their flavor.
Pour in the tomato sauce, diced tomatoes with their juices, kidney beans, and beef broth. Stir to combine, scraping the bottom of the pan to release any browned bits. Bring the mixture to a gentle simmer, then reduce the heat to medium-low.
Simmer uncovered for 10–15 minutes, stirring occasionally, until the chili has thickened slightly and tastes rich and well-seasoned. Taste and adjust salt, pepper, or heat level as desired. Turn off the heat and set aside while you make the cheese sauce.
Step 5: Make the Ultra-Cheesy Sauce
In a separate large saucepan or the pot you used for pasta, melt 4 tablespoons of butter over medium heat. Once melted and foamy, whisk in the 1/4 cup of flour. Cook, whisking constantly, for about 1 minute. The mixture (a roux) will look like a thick paste and should smell slightly nutty, but it should not brown.
Gradually pour in the warm milk, a little at a time, whisking constantly to avoid lumps. Once all the milk is added, continue cooking and whisking for 4–6 minutes until the sauce bubbles gently and thickens to about the consistency of light cream.
Turn the heat down to low. Whisk in the Dijon mustard, garlic powder, onion powder, 1/2 teaspoon smoked paprika, and 3/4 teaspoon kosher salt. Taste and adjust seasoning if needed.
Remove the pot from the heat. Add 2 cups of shredded cheddar, 1 cup of shredded Monterey Jack, and the cream cheese cubes (if using). Stir slowly until all the cheese is melted and the sauce is smooth, glossy, and thick. If it seems overly thick, you can whisk in a splash of milk to loosen it slightly; it should be pourable but still rich.
Step 6: Combine Pasta, Chili, and Cheese Sauce
In a very large mixing bowl or in the pot you used for the cheese sauce, combine the drained macaroni and the warm cheesy sauce. Fold gently with a spatula or large spoon until every piece of pasta is coated.
Add the warm smoky beef chili to the cheesy pasta mixture. Stir gently but thoroughly until the chili is evenly distributed and everything looks well combined, forming a thick, saucy chili mac mixture.
Transfer this mixture into the prepared 9×13-inch baking dish, smoothing the top into an even layer.
Step 7: Top with Cheese and Bake
Sprinkle the remaining 1 cup of shredded cheddar and 1/2 cup of shredded Monterey Jack evenly over the top of the casserole. If you like a bit of extra color, you can lightly dust the top with an extra pinch of smoked paprika or black pepper.
Place the baking dish in the preheated 375°F (190°C) oven. Bake for 15–20 minutes, or until the cheese on top is melted and bubbly and the edges are just beginning to brown. If you prefer a more golden top, you can broil for 1–2 additional minutes, watching very closely to prevent burning.
Step 8: Rest, Garnish, and Serve
Remove the chili mac and cheese from the oven and let it rest for 5–10 minutes. This short resting time helps the casserole set slightly so it scoops more neatly, while still staying deliciously molten inside.
Just before serving, sprinkle the top with chopped cilantro or parsley and sliced green onions. Add optional toppings like sliced or pickled jalapeños and small dollops of sour cream if you like some cool creaminess against the smoky heat.
Scoop generous portions into bowls or onto plates and enjoy warm.
Pro Tips
- Undercook the pasta slightly: Stopping the macaroni 1–2 minutes before full al dente prevents it from becoming overly soft after baking.
- Shred your own cheese: Pre-shredded cheese often contains anti-caking agents that make sauces grainy. Freshly grated cheese melts smoother and gives a silkier sauce.
- Control the spice level: For mild chili, skip the chipotle or cayenne. For more heat, add extra chipotle powder or a minced jalapeño to the chili.
- Use a wide pan for the chili: A broad surface area helps the chili reduce and thicken faster, concentrating the flavor.
- Let it rest before serving: That 5–10 minute rest makes the difference between a runny casserole and beautiful, scoopable portions that still feel gooey and indulgent.
Variations
- One-Pot Skillet Version: If you have a large, oven-safe Dutch oven or deep skillet, you can cook the chili and cheese sauce in the same pot, stir in the pasta, top with cheese, and bake directly in that pan.
- Turkey or Chicken Chili Mac: Swap the ground beef for ground turkey or chicken. Use chicken broth instead of beef broth, and add 1 tablespoon tomato paste for a deeper flavor.
- Extra-Veggie Version: Stir in 1–2 cups of extra vegetables such as corn, diced zucchini, or finely chopped carrots with the onions and peppers to boost nutrition and texture.
Storage & Make-Ahead
To store leftovers: Let the casserole cool to room temperature, then cover tightly or transfer to airtight containers. Refrigerate for up to 4 days. Reheat individual portions in the microwave, adding a splash of milk if it seems dry, or rewarm the whole dish covered with foil in a 350°F (175°C) oven for 20–25 minutes.
To make ahead (unbaked): Assemble the casserole up through Step 6, cover tightly, and refrigerate for up to 24 hours. When ready to bake, let 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.
To freeze: Assemble, cool, wrap well (plastic wrap plus foil), and freeze for up to 2 months. Thaw overnight in the refrigerator and bake covered at 350°F (175°C) for 30–40 minutes, then uncover and bake 10 more minutes until bubbly.
Nutrition (per serving)
Approximate values for 1 of 8 servings: about 680 calories; 33 g protein; 32 g fat; 60 g carbohydrates; 4–5 g fiber; 10 g sugar; 980 mg sodium. Values will vary based on specific brands of ingredients, cheese types, and added toppings.
