Preheat your oven to 350°F (175°C). Place a sheet pan or aluminum foil on the lower rack to catch any drips during baking. This simple step prevents oven cleanup later.

Bring a large pot of heavily salted water to a rolling boil. Add your cavatappi (or elbow macaroni) and cook 1–2 minutes shy of al dente according to package directions. The pasta will continue cooking during baking, so undercooking slightly prevents mushiness. Drain in a colander and set aside without rinsing-the starch helps the cheese sauce cling better.

Heat your Dutch oven or deep skillet over medium-high heat. Add a small drizzle of neutral oil if needed. Add the ground beef in an even layer and resist the urge to stir immediately-let it develop a beautiful brown crust for 2–3 minutes before breaking it up with your spoon. This caramelization adds depth to your chili mac.

Once the beef is mostly browned, add the diced onion, bell pepper (or jalapeños for heat), and minced garlic. Cook for 3–4 minutes, stirring occasionally, until the vegetables soften and become fragrant.

Stir in the tomato paste and cook for 1 minute to remove its raw flavor. Add all your spices: chili powder, ancho chili powder, ground cumin, all-purpose seasoning, and garlic pepper. Stir constantly for 30–60 seconds until the spices become aromatic-this blooming technique intensifies their flavors.

Pour in the tomato sauce, drained beans, Worcestershire sauce, honey, and hot sauce if using. Stir thoroughly, scraping up any flavorful browned bits from the bottom of the pot. Bring to a simmer, then reduce heat to low and let cook for 20–30 minutes, stirring occasionally. The chili should thicken and the flavors will meld beautifully. Taste and adjust salt and pepper as needed.

While your chili simmers, prepare the cheese sauce in a separate large pot. Melt 2 tablespoons of butter over medium heat. Add the chicken bouillon powder and garlic pepper seasoning, stirring to combine. Pour in the heavy cream and bring to a gentle simmer. Let it reduce and thicken slightly for 8–12 minutes, stirring occasionally.

Turn off the heat completely. Gradually whisk in all the shredded cheeses-sharp cheddar, Colby Jack, and Fontina-a handful at a time, stirring until each addition melts completely and the sauce is smooth and creamy. If the sauce seems too thick, add a splash of reserved pasta water to reach your desired consistency. Taste and adjust seasoning.

Add your cooked cavatappi to the cheese sauce and stir gently but thoroughly to coat every piece of pasta.

Add about ¾ of the mac and cheese mixture into the chili pot. Reserve the remaining cheese sauce if your mixture looks too soupy-you can always add more. Stir everything together until beautifully combined and creamy, ensuring the chili and mac are fully incorporated.

Transfer the entire chili mac mixture to a greased 9×13-inch baking dish, spreading it evenly. Top generously with the remaining 8–10 oz of shredded Colby Jack or cheddar cheese, covering the surface completely.

Place the dish in your preheated 350°F oven and bake for 25–30 minutes until the cheese on top is bubbly, melted, and golden brown in spots.

While your chili mac bakes, prepare the panko topping for added texture. Melt 4 tablespoons of butter in a skillet over medium heat. Add the panko breadcrumbs and toast, stirring frequently, until golden brown. Remove from heat and stir in the Parmesan cheese, chili powder, and garlic pepper seasoning. Once your baked dish comes out of the oven, immediately sprinkle this warm panko mixture over the top for an irresistible crunch.

Let the dish rest for 10–15 minutes before serving. This resting period allows the sauce to set up properly, making it easier to serve neat portions. Garnish with chopped fresh parsley or cilantro for color and freshness. Serve hot with cornbread, crusty bread, or Cheddar Bay biscuits on the side.