How to make Grogu: 5 puppeteers, stunts and improvisation that bring the Star Wars ‘daddy’s boy’ to life

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I remember when The Mandalorian first came out in 2019 – everyone instantly fell in love with Grogu, though we only knew him as ‘Baby Yoda’ back then! He quickly became one of the most popular characters in the whole Star Wars universe, honestly.

It’s quite an accomplishment, considering the series is known for its memorable characters – from human heroes like Luke Skywalker and Princess Leia to distinctly alien ones like Chewbacca and R2-D2.

Grogu, the beloved character from The Mandalorian, will star in his own movie alongside Din Djarin. The film, releasing in theaters on May 22nd, will follow the pair on a new mission to save Rotta the Hutt.

Similar to how Yoda was originally created in The Empire Strikes Back, Grogu is brought to life using puppets, and a great deal of work happens behind the scenes to make him move and feel real.

We talked to lead puppeteer Mike Manzel to find out exactly how Grogu comes to life on screen. Here’s a detailed look at how his movements, expressions, and even complex scenes – like a recent swimming sequence – are achieved.

Baby steps

My path to becoming a puppeteer wasn’t direct. I started with studies in art and digital communications, followed by an internship at an animation studio and some commercial work. But I always dreamed of working with puppets and special effects – a dream sparked by seeing Star Wars as a kid! I’ve contributed to many films, like Kill Bill and Jurassic World, but working on The Mandalorian and bringing Grogu to life felt like everything had come full circle.

As a huge fan of the way they brought Grogu to life, I’ve been fascinated by the team effort behind it. It’s amazing how they combine puppetry and animatronics! I personally operate his arms, and I’m always using a rod connected to his body to make his movements feel natural – which means I’m often right there on set and then digitally removed later. Dawn Dininger handles the legs, while Jason Matthews remotely controls his eyes – they’re so expressive, and those eyes are key to everything! Victor Broadley is in charge of the ears and mouth, giving Grogu that adorable little smile. And finally, Trevor Hensley controls all his head movements. It really takes a village to make him so believable!

Working with the visual effects team is a lot like playing in a jazz band – it requires a lot of preparation and practice. We’ll analyze the script, like figuring out how to show someone throwing something at Grogu. We’ll then rehearse the scene and film it, getting feedback from director Jon Favreau. But just like jazz, there’s also room for spontaneity. Jon might tell us, ‘Grogu is feeling sad in this scene,’ and we’ll respond and bring that emotion to life through our work!

Learning the basics

Grogu is incredibly expressive, especially through his eyes. They really show what he’s feeling! When he uses the Force, his eyes narrow and his brow furrows, showing his concentration. Droopy ears indicate sadness. Getting these emotions across requires a strong connection between all of us working on the show – we really have to feel what he’s feeling. It can be tricky because there’s limited space inside the puppet to create expressions. However, we’ve always found creative ways to show even complex feelings like frustration. Overall, he manages to convey emotions remarkably well!

Grogu’s unique way of walking has changed over time. In the first season, he was often in his carrier or being held, and we didn’t use any supports for his feet. I would essentially float just above him and guide him to create a little trot. It wasn’t until ‘The Book of Boba Fett’ that we started using supports on his feet to make him take small, quick steps.

Puppetry and animatronics have limitations. For example, Grogu can’t clap – a fact Conan O’Brien jokingly pointed out at the Oscars, which was a little awkward for us! We’re constantly working to push the boundaries of what’s possible with the physical puppet, but some shots are just too complex. That’s where the team at Industrial Light & Magic steps in with CGI. They’re incredibly skilled at making the digital effects blend seamlessly with the puppet’s movements, so hopefully you can’t even tell what’s real and what’s computer-generated.

New challenges for the ‘daddy’s boy’

Working with the Mandalorian and Grogu came with many difficulties for the team controlling the puppet. One major challenge was filming scenes of Grogu swimming – puppets and electronics don’t handle water well! While we used several puppets for filming, including detailed ‘hero’ versions and those for stunts, we also had to create a special waterproof puppet. My colleague Dawn and I spent most of our days in the water, working to make those scenes happen and avoid getting submerged!

Pedro Pascal is very fond of Grogu, who’s become like a son to his character. However, in this project, Grogu feels more like a teammate. When filming, the actors concentrate on interacting with the Grogu puppet itself, not the puppeteers. Even though puppeteers control Grogu’s movements, the actors respond to what’s said to the puppet, as if it were a single, living character – which makes things much simpler than trying to react to five different puppeteers!

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The Mandalorian & Grogu is coming to cinemas on Friday 22 May 2026.

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Authors

Stephen Kelly

Stephen Kelly is a journalist who covers culture and science. He’s the editor of the ‘Popcorn Science’ feature for BBC Science Focus, where experts each month discuss how realistic new movies and TV shows are. His work also appears in publications like The Guardian, The Telegraph, and Wired. He enjoys Studio Ghibli films, supports Tottenham Hotspur, and has a fondness for writing about himself in the third person.

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2026-05-18 17:36