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Tudyk's television roles include Wash on the space Western drama series Firefly (2002–2003). The show ran for one season and developed a cult following after the series aired. He reprised the role in the 2005 continuation film Serenity, expanding on the events of the final episode of the series. His other roles include the 2007 English black comedy film Death at a Funeral, the sitcom Arrested Development (2005, 2013, 2019), the science fiction series Dollhouse (2009–2010), the superhero animated series Young Justice (2010–2013, 2019), and various voices on the animated series American Dad! (2011–present). Tudyk played Dr. Noah Werner on the sitcom Suburgatory (2011–2014). He also starred in the comedy series Newsreaders (2014–2015), the animated series Star vs. the Forces of Evil (2015–2019), voiced Dangerboat in the series The Tick (2017–2019), played K-2SO in the 2016 film Rogue One, and Eric Morden/Mr. Nobody on the series Doom Patrol (2019). In video games, he voiced Mickey in Halo 3: ODST (2009) as well as reprising his roles as K-2SO in Star Wars Battlefront (2015) and as the Green Arrow in various DC Super Hero Video Games (2013, 2015, & 2017).

Since 2019, Tudyk has voiced The Joker and Clayface in the series Harley Quinn. Tudyk plays Dr. Harry Vanderspeigle in the science fiction comedy series Resident Alien and voices Optimus Prime in the animated series Transformers: EarthSpark.