Tudyk was born in El Paso, Texas, the son of Betty Loyce (née Wiley) and Timothy Nicholas Tudyk. His father is of Polish descent and his mother has German, English, and Scottish ancestry. He was raised in Plano, Texas, a suburb of Dallas, where he attended Plano Senior High School. He had a brief experience as a stand-up comic, before quitting after an angry audience member threatened to kill him. Tudyk studied drama at the Methodist-affiliated Lon Morris College in Jacksonville, Texas where he won the Academic Excellence award for drama. While in college, he played Beaver Smith in an eastern New Mexico summer stock theater production of Billy the Kid. Tudyk entered Juilliard but left in 1996 before earning a degree.
In 2000, Tudyk played Gerhardt, a gay German drug addict, alongside Sandra Bullock and Viggo Mortensen in 28 Days. He played Wat in 2001's A Knight's Tale, Steve the Pirate in the 2004 comedy Dodgeball: A True Underdog Story and Sonny in I, Robot.
In 2007, Tudyk had a supporting role as a strong-willed doctor in the western film 3:10 to Yuma alongside Christian Bale and Russell Crowe along with a brief but memorable role in the film Knocked Up and a highly physical comedic performance in the British film Death at a Funeral.
Tudyk voiced the Duke of Weselton in Disney's 2013 film Frozen. In 2014, he voiced Alistair Krei in Disney's Big Hero 6, and in 2016, he voiced Duke Weaselton and Hei Hei in Disney's Zootopia and Moana, respectively. That same year, he played the droid K-2SO in Rogue One: A Star Wars Story.
Tudyk is currently a main cast member on the DC Comics-based comedy show Powerless.
|Star vs. the Forces of Evil Staff|