We study the geometry of warped cones over free, minimal isometric group actions and related constructions of expander graphs. We prove a rigidity theorem for the coarse geometry of such warped cones: Namely, if a group has no abelian factors, then two such warped cones are quasi-isometric if and only if the actions are finite covers of conjugate actions. As a consequence, we produce continuous families of non-quasi-isometric expanders and superexpanders. The proof relies on the use of coarse topology for warped cones, such as a computation of their coarse fundamental groups.From the above expression, it is clear the large-scale geometry of these level sets is invariant under taking finite quotients or extensions of the action: Lemma 2.3. Let F ⊆ Γ be a finite normal subgroup, and write Γ := Γ/F and M := M/F . Write M t (resp. M t ) for the level set at time t of the cone over Γ M (resp. Γ M ). Then M t is (1, B)-quasi-isometric to M t , where B is the maximal word length in Γ of an element of F .Proof. Write π : M t → M t for the natural quotient map. It is easy to see that π is distance non-increasing, i.e. 1-Lipschitz. For the lower bound, let C be the maximal word length of an element of the finite group F . Further