Alan Tudyk recently revealed an intriguing behind-the-scenes story about his involvement in the 2004 film I, Robot, which starred Will Smith. Tudyk provided the voice and motion capture for Sonny, the central robot character. Despite the significance of his role, many viewers were unaware that he was behind the character. Tudyk explained on the "Toon’d In with Jim Cummings" podcast that his relative obscurity in relation to I, Robot was no accident. During the film’s test screenings, audiences unexpectedly responded more positively to his character than to Will Smith's lead role. This surprising outcome led to Tudyk being removed from the film's publicity and promotional materials. Essentially, the studio chose to downplay his involvement to maintain the focus on Smith, the film's star.

Tudyk recounted that test screening feedback showed him "scoring higher than Will Smith" in terms of character reception. After receiving this feedback, the marketing strategy shifted decisively, and his name was excluded from the promotional campaigns. This deliberate sidelining meant that despite his intense preparation and performance—which included physically embodying the robot through motion capture and voice acting—his contribution was largely invisible to the public. Tudyk expressed disappointment and surprise, saying he was "very upset" and shocked no one would recognize his role in the film. His portrayal of Sonny marked an early use of motion capture technology in Hollywood, a technique he would later revisit in roles like the droid K-2SO in Rogue One: A Star Wars Story and the show Andor.

I, Robot, directed by Alex Proyas, is set in a futuristic 2035 Chicago where robots perform various public service duties. Will Smith plays Detective Del Spooner, who investigates the suspicious death of a robotics company’s founder. The plot thickens as Spooner suspects that Sonny, Tudyk’s robot character, might be responsible. The film features a notable cast including Bridget Moynahan, Bruce Greenwood, and James Cromwell. It also earned an Oscar nomination for Best Visual Effects, underscoring its technical achievements. Despite Tudyk’s crucial role in bringing Sonny to life, the promotional focus remained firmly on Smith, highlighting the commercial pressures behind marketing blockbuster films and the desire to keep star power front and center.

Reflecting on his experience, Tudyk highlighted the emotional and physical dedication he invested in the role. He had to master robotic movement nuances and voice the complex character convincingly, only to see that work minimized in the film’s publicity. Tudyk’s revelation shines a light on the sometimes harsh realities actors face in Hollywood, where marketing decisions can overshadow creative contributions. His story also underscores the evolving role of motion capture technology in modern filmmaking, marking I, Robot as an early example of this transformation within the industry.