This hearty Ham and Potato Casserole is a comforting dish perfect for family meals or using up leftover ham. Layers of tender russet potatoes, savory diced ham, and sweet sautéed onions are baked in a rich, creamy sharp cheddar cheese sauce until golden and bubbly. It's a satisfying, easy-to-prepare one-pan meal that promises warmth and flavor in every forkful.
For the best texture, ensure potatoes are sliced uniformly—about 1/4-inch thick—to guarantee even cooking. Partially pre-boiling the potatoes before layering can significantly reduce baking time and ensure a tender, not crunchy, result. When preparing the cheese sauce, cook the roux (butter and flour) for at least a minute to eliminate any raw flour taste before gradually whisking in cold milk to prevent lumps. Using freshly grated sharp cheddar will yield a smoother, creamier sauce compared to pre-shredded cheese, which often contains anti-caking agents. A touch of dry mustard or a pinch of freshly grated nutmeg in the cheese sauce can elevate the overall flavor profile. For an extra layer of texture, consider topping the casserole with a mixture of panko breadcrumbs and melted butter during the last 15 minutes of baking.