Alan Tudyk initially turned down the role of K-2SO because the start of filming clashed with pre-production of his crowdfunded comedy series Con Man (2015). When Gareth Edwards told him that the filming was moved back by a month in July 2015, he agreed to join the production. To prepare for the role he took mask lessons with a New York-based mask teacher Orlando Pabotoy, to learn to express more through body language. He has since said that the role was one of the best he had worked on because it allowed him to wear a motion-capture suit on set along with the bonus of walking on 13-inch stilts. Tudyk filmed a brief scene where he appears as Wray Nerely, his character from "Con Man", but it ended up getting deleted.

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