Heat the oven to 375°F and grease a 9-by-13-inch dish. Cook cavatappi 2 minutes short of done and drain.
Melt butter in a skillet, add onions and sugar and cook 18 to 22 minutes until deep golden. Add beef and brown, then drain excess fat.
Stir in flour for 1 minute, then broth, Worcestershire, thyme, salt and pepper and simmer until thickened.
Fold in pasta and 1 1/2 cups Gruyère. Spread in the dish and top with remaining cheese.
Bake for 25 to 30 minutes until bubbling and browned. Rest 10 minutes.