Alan Tudyk Says He Outscored Will Smith in I, Robot Test Screenings — Then Disappeared from the Marketing
Alan Tudyk is a master of bringing robots to life. Whether it’s the sarcastic, scene-stealing K-2SO in Rogue One: A Star Wars Story and Andor, or the hilariously endearing Gary in My Adventures with Superman, Tudyk has built a career on giving mechanical characters depth, humor, and humanity. But one of his earliest robot roles came with a twist he didn’t see coming — and it involved Will Smith.
In a recent appearance on the podcast Toon’d In with Jim Cummings, Tudyk revealed that his performance as Sonny, the sympathetic NS5 robot in the 2004 sci-fi hit I, Robot, tested so well with audiences that it actually outscored the film’s star.
And according to Tudyk, that’s exactly why he was erased from the film’s marketing campaign.
“You Tested Higher Than Will Smith”
“They were doing test audiences for the movie,” Tudyk recalled. “They score the characters in this kind of test screening. I got word back: ‘Alan, you are testing higher than Will Smith.’ And then I was gone. I was done. There was no publicity, and my name was not mentioned.”
It was a frustrating moment for Tudyk, who had poured himself into the role, performing both the voice and motion capture for Sonny — a groundbreaking feat at the time.
“I was so shocked,” he said. “I was like, ‘Wait, nobody is going to know I’m in it!’ I put a lot into [that performance]. I had to move like a robot. At the time, I was very upset.”
The Unspoken Rule in 2004
In hindsight, the decision makes a certain Hollywood sense — even if it feels unfair. Back in the early 2000s, performance capture acting was still relatively new. Aside from Andy Serkis’ widely praised Gollum in The Lord of the Rings, most digital characters were marketed as special effects achievements, not star performances.
The studio likely didn’t want the press or audience attention shifting away from Will Smith, who was the marquee name and box-office draw. For Tudyk, however, it meant losing credit for what became one of the most memorable performances in the film.
Sonny: The Heart of I, Robot
Looking back, it’s easy to see why Sonny resonated so strongly with audiences. In a film filled with distrust toward artificial intelligence, Sonny stands apart — curious, self-aware, and capable of emotions. His arc, from being accused of murder to becoming the key to stopping a rogue AI plot, gave the movie its heart.
Meanwhile, Smith’s character, Detective Del Spooner, was written as a skeptical, technophobic loner. The contrast between Sonny’s emotional warmth and Spooner’s guarded cynicism made the robot the more likable figure for many viewers.
Tudyk’s Ongoing Legacy as Hollywood’s Go-To Robot
If anything, I, Robot marked the beginning of Tudyk’s long and varied career playing mechanical beings. He went on to:
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K-2SO in Rogue One and Andor — a sardonic reprogrammed Imperial droid who became a fan favorite.
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Alan the Robot in Ralph Breaks the Internet.
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Gary / Robot #5 in My Adventures with Superman (2024).
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Various voice roles for animated series and video games, often leaning into robotic or otherworldly characters.
In many ways, Tudyk has become to robots what Andy Serkis is to mo-cap creatures — the go-to actor for giving pixels a soul.
Then vs. Now: Recognition for Performance Capture
Performance capture has come a long way since 2004. Actors like Serkis, Zoe Saldaña, and Josh Brolin have received widespread praise for their work in digitally enhanced roles. Tudyk himself is now widely celebrated for his contributions to the craft.
Today, it’s hard to imagine a major studio erasing a performer’s involvement in such a role — especially when the actor delivers a standout performance.
Still, the I, Robot incident remains a reminder of how much Hollywood has shifted in the past two decades when it comes to acknowledging the talent behind digital characters.
A Missed Opportunity for the Studio?
Ironically, keeping Tudyk out of the marketing might have been a missed opportunity. While Will Smith’s star power carried the box office, promoting Sonny as a breakthrough performance-capture character could have positioned I, Robot alongside films like The Lord of the Rings and Avatar in terms of technological achievement.
Instead, Tudyk’s role became something of an industry trivia fact — the kind of thing fans only discovered years later.
Tudyk’s Good-Humored Reflection
Time has softened Tudyk’s frustration. These days, he speaks about the experience with a mix of disbelief and humor. And while his name may not have been in the press back in 2004, the performance itself has stood the test of time.
For many fans, Sonny remains the highlight of I, Robot — a character they connected with emotionally, even through layers of CGI. And now that Tudyk has told the story, it’s clear just how much of Sonny’s humanity came directly from the man behind the motion capture suit.
Bottom Line:
Alan Tudyk’s revelation is more than just a quirky Hollywood anecdote — it’s a snapshot of a time when the rules of stardom often overshadowed artistry. Two decades later, Tudyk’s Sonny is still the beating heart of I, Robot, and now fans finally know exactly who brought him to life.
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