Chili Mac Casserole Recipe

There's something magical about a bubbling Chili Mac Casserole Recipe fresh from the oven. The aroma of seasoned ground beef, tangy tomatoes, and melted cheese fills your kitchen and instantly brings everyone to the table. I've been making this Chili Mac Casserole Recipe for years, and it never fails to disappear within minutes.

This Chili Mac Casserole Recipe combines two beloved comfort foods into one irresistible dinner dish. It's budget-friendly, takes just 30 minutes from start to finish, and uses ingredients you probably already have in your pantry. Whether you're feeding picky kids or hosting a casual get-together, this Chili Mac Casserole Recipe delivers every single time.

What Makes This Comfort Food Champion Stand Out

This isn't your average pasta bake. What sets this cheesy chili mac apart from other casseroles is how it balances rich, savory flavors with a creamy texture that keeps you coming back for more. The ground beef pasta bake technique creates layers of flavor that develop as everything bakes together, while the cheese melts into every corner of the dish. My Chili Mac Casserole Recipe uses a simple one-pot method that cuts down on cleanup without sacrificing taste.

The beauty of this family dinner casserole lies in its versatility. You can adjust the spice level for sensitive palates or crank up the heat for those who love a kick. It works beautifully as a weeknight comfort food recipe when time is tight, yet it's impressive enough for potluck gatherings. This Chili Mac Casserole Recipe has roots in classic American comfort cooking, where hearty meals brought families together around the dinner table. The combination of chili and macaroni creates a Tex-Mex pasta bake that satisfies even the heartiest appetites.

Jump to:

• Ingredients
• Instructions
• Recipe Variations & Substitutions
• Equipment Recommendations
• Storage & Meal Prep Tips
• The Secret That Changed Everything
• FAQ
• Wrap-Up: Your New Weeknight Winner
• Related
• Pairing
• Chili Mac Casserole Recipe

Ingredients

For the Base

• Ground beef
• Onion, diced
• Garlic, minced
• Kidney beans, drained
• Diced tomatoes
• Tomato sauce

For the Pasta & Cheese

• Elbow macaroni
• Shredded cheddar cheese
• Shredded mozzarella
• Sour cream

Seasonings

• Beef broth
• Chili powder
• Cumin
• Paprika
• Salt
• Black pepper

See recipe card for quantities.

Instructions

Brown the Beef and Build Flavor

1. Preheat your oven to 375°F and lightly grease a 9x13 inch baking dish.
2. Heat a large skillet over medium-high heat and add the ground beef.
3. Break up the meat with a wooden spoon and cook for 5-6 minutes until browned.
4. Add the diced onion and cook for another 3 minutes until softened.
5. Stir in the minced garlic and cook for 30 seconds until fragrant.
6. Drain excess fat if needed, leaving about 1 tablespoon for flavor.

Add Chili Components

1. Sprinkle the chili powder, cumin, paprika, salt, and pepper over the beef mixture.
2. Stir everything together and let the spices toast for about 1 minute.
3. Pour in the diced tomatoes, tomato sauce, and beef broth.
4. Add the kidney beans and stir to combine.
5. Bring the mixture to a simmer and let it cook for 5 minutes to blend the flavors.
6. Remove from heat and taste; adjust seasonings as needed.

Cook Pasta and Combine

1. While the chili simmers, cook the elbow macaroni according to package directions until just al dente.
2. Drain the pasta well and return it to the pot.
3. Add the chili mixture to the cooked macaroni and stir to combine.
4. Fold in the sour cream and 1 cup of the cheddar cheese.
5. Mix until the cheese starts to melt and everything is evenly distributed.
6. Transfer the entire mixture to your prepared baking dish.

Top and Bake to Perfection

1. Let the hearty pasta comfort food rest for 5 minutes before serving; this allows the casserole to set and makes serving easier.
2. Spread the mixture evenly in the baking dish.
3. Combine the remaining cheddar and mozzarella cheese in a bowl.
4. Sprinkle the cheese mixture generously over the top of the casserole.
5. Cover with aluminum foil and bake for 20 minutes.
6. Remove the foil and bake for an additional 10 minutes until the cheese is bubbly and golden.

Expert Cooking Tips

• Perfect Meat Texture Don't over-stir the ground beef while browning. Let it sit for a minute or two to develop a nice crust, which adds incredible flavor to your easy chili mac recipe. If the meat releases too much liquid, drain it halfway through cooking to ensure proper browning.
• Pasta Cooking Secrets Undercook your macaroni by about 2 minutes less than the package directions suggest. Since it continues cooking in the oven, this prevents mushy pasta. Salt your pasta water generously; it should taste like the sea. This is your only chance to season the pasta itself.
• Cheese Melting Magic Bring your cheese to room temperature before adding it to the dish. Cold cheese doesn't melt as smoothly and can create a grainy texture. Mix different cheese varieties for complex flavor; try adding Monterey Jack or pepper jack for extra creaminess and a spicy kick.
• Spice Level Control Start with half the chili powder if you're serving kids, then offer hot sauce at the table for adults. Add a pinch of cinnamon to your chili mixture for depth without heat. This old restaurant trick adds complexity that people notice but can't quite identify.
• Make-Ahead Strategy Assemble the entire casserole up to 24 hours in advance, but hold off on adding the top layer of cheese. Cover tightly with plastic wrap and refrigerate. When ready to bake, add the cheese and increase baking time by 10 minutes since it's starting cold.
• Moisture Management If your chili mac with ground beef looks dry before baking, add an extra ¼ cup of beef broth. The pasta absorbs liquid as it bakes, so slightly saucy is better than dry. Check halfway through baking; if the edges look dry, add a splash of broth around the perimeter.

Recipe Variations & Substitutions

Dietary Modifications

• Gluten-Free Version Swap regular elbow macaroni for your favorite gluten-free pasta. Brown rice pasta or chickpea pasta both work wonderfully in this budget-friendly pasta bake. Just watch the cooking time, as gluten-free pasta can turn mushy quickly.
• Vegetarian Adaptation Replace the ground beef with a plant-based alternative or use a combination of black beans and pinto beans for protein. Add diced bell peppers and zucchini for extra vegetables. You'll get the same hearty texture with a lighter feel.
• Low-Carb Option Use cauliflower florets instead of macaroni for a keto-friendly version. Steam the cauliflower until just tender, then proceed with the recipe as written. This cuts the carbs dramatically while maintaining that satisfying casserole experience.

Flavor Variations

• Spicy Southwestern Style Transform this into a spicy chili mac by adding diced jalapeños, a can of green chiles, and using pepper jack cheese instead of cheddar. Top with crushed tortilla chips before the final bake for added crunch and flavor.
• Creamy Ranch Version Mix in a packet of ranch seasoning with the chili spices and replace the sour cream with cream cheese. This creates an ultra-creamy chili casserole that kids absolutely love. Top with crumbled bacon before serving.
• Italian-Inspired Twist Use Italian sausage instead of ground beef and swap the chili powder for Italian seasoning. Add a layer of marinara sauce and top with Parmesan cheese for a fusion dish that bridges two comfort food worlds.
• BBQ Chili Mac Stir in ¼ cup of your favorite barbecue sauce with the chili mixture. This adds a subtle sweetness that balances the spices perfectly. Top with crispy fried onions during the last 5 minutes of baking.

Equipment Recommendations

• Large cast-iron skillet or Dutch oven ; perfect for browning meat and building flavors in this meal prep casserole dish
• 9x13 inch baking dish ; the standard size works perfectly for family portions (glass or ceramic both work well)
• Large pot for boiling pasta ; at least 4-quart capacity ensures pasta cooks evenly
• Wooden spoon or heat-resistant spatula ; for stirring without scratching your cookware
• Sharp chef's knife ; makes quick work of chopping onions and garlic
• Cheese grater ; freshly shredded cheese melts better than pre-shredded varieties
• Aluminum foil ; for covering during the initial bake to prevent over-browning
• Colander ; for draining pasta quickly and efficiently

Storage & Meal Prep Tips

Refrigerator Storage

• Store leftover kid-friendly chili mac in an airtight container for up to 4 days in the refrigerator. The flavors actually improve overnight as everything melds together. Reheat individual portions in the microwave for 2-3 minutes, stirring halfway through. For oven reheating, cover with foil and warm at 350°F for 15-20 minutes.

Freezing Instructions

• This casserole freezes beautifully for up to 3 months. Cool completely before freezing to prevent ice crystals. Divide into individual portions using freezer-safe containers for easy grab-and-go meals. To reheat from frozen, thaw overnight in the refrigerator, then reheat in the oven at 350°F for 25-30 minutes covered, then 10 minutes uncovered.

Make-Ahead Strategy

• Prepare the entire casserole in a disposable aluminum pan for easy gifting or potluck transport. Assemble everything except the final cheese topping up to 2 days ahead. When ready to serve, bring to room temperature for 30 minutes, add cheese, and bake as directed. This makes weeknight dinners incredibly easy when you prep on Sunday.

FAQ

Wrap-Up: Your New Weeknight Winner

This Chili Mac Casserole Recipe proves that comfort food doesn't have to be complicated or time-consuming. With simple ingredients and straightforward steps, you've got a dish that feeds a crowd, satisfies picky eaters, and creates those cozy dinner moments families treasure. The best part? You can customize this Chili Mac Casserole Recipe to match your family's tastes and dietary needs.

Once you've mastered this hearty classic, why not try our Veggie Potato Recipe for a lighter side dish that pairs beautifully with this pasta bake? Or explore our Minced Beef Pie Recipe for another ground beef dinner idea that's perfect for meal prep. Both recipes share that same comforting quality that makes this Chili Mac Casserole Recipe such a winner. Give it a try tonight and watch it become a permanent fixture in your dinner rotation.

With love from my kitchen to yours
By Lisa Johnson 💌

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