You know him. You do. He’s the guy who pops up onscreen and makes you guffaw, cringe or both at the same time. Yet fans usually have to search Sean Whalen’s name before approaching him out in the wild.

“I know when someone recognizes me,” Whalen tells Yahoo. “It's the walk by, then I look back and [they’re whispering]. I’ll go over and say hi, shake their hand, meet them. Sometimes, somebody might come up and go, ‘Are you Sean Whalen?’ and I say, ‘You Googled that, didn't you?’ They go, ‘yes’ — because they know my face, they just don't know my name.”

That’s the life of a career character actor. Whalen, 61, has been here, there and everywhere in Hollywood productions, always delivering memorable performances, even if his name isn’t at the tip of the tongue. Or you mistake him for Steve Buscemi, which happens a lot too.

“With my fans, if you're 20 to 30, you know me from Disney Channel [Wizards of Waverly Place],” says Whalen, whose Instagram describes him as “That Guy.” “If you're a 30- to 50-year-old woman, you know me from Never Been Kissed, That Thing You Do! and maybe Employee of the Month. If you’ve got tons of tattoos or you know me from horror, it’s The People Under the Stairs. The Black community knows me from [My Wife and Kids]. And if I'm in the Midwest, forget it. It's Twister all day long.”

His Hollywood breakthrough is a helluva story, involving milk, peanut butter, Michael Bay and Steven Spielberg. Whalen performed and studied at the Groundlings Theater and Playhouse West in Los Angeles, and commercials became his bread and butter — until one he did became bigger than him.

Whalen has the distinction of appearing in the first “Got Milk?” ad, back in 1993. It was initially for the California Milk Processor Board, with an ad agency given “creative carte blanche” to sell milk because sales had dipped. Long before Hamilton’s domination, the pitch was an Aaron Burr–themed commercial directed by Bay, the man behind big-budget blockbusters like Bad Boys and Armageddon.

“That commercial got him his movie career — and me my acting career,” Whalen says. “It was well-written and shot beautifully. Bay told a huge beginning, middle and end story in a minute. But I improvised that role in my audition. They didn't have an ending yet. [Other actors] played it mad — smashing and throwing things. I was the only one who was like, My life is over. What have I done?” In the ad, Whalen’s history buff character is unable to speak clearly — his peanut butter sandwich stuck to the roof of his mouth — when a radio show calls to have him answer a trivia question. Hence, Aaron Burr comically coming out as “Aawun Buhh.”

The popularity of the commercial bumped milk sales 25%, Whalen says, and as a result, the spot aired all the time. However, because it was a local ad, “You only get $1,100 a quarter,” the actor says. “Every three months, I made $400. So I basically made $125 a month — and this thing was running day and night.”

The campaign later went national, making it more lucrative — with an asterisk.

“That's when I made some money for a little while,” he says. “But I couldn't get any other commercials because I had become ‘the milk guy.’ If you're selling Chevy trucks and you see me in there, you go, ‘Oh, the milk guy’s in a truck.’ You don’t want that. So it killed my commercial career, but it launched my theatrical career.”

Enter Spielberg. The renowned director, who often used unknown actors, was producing the 1996 disaster film Twister and cast Whalen as storm chaser Sanders.

“Oh God, I was so nervous,” he says. “I thought, ‘They're going to find out I'm just a commercial actor.’ But I held my own.”

Whalen had the time of his life chasing storms with Alan Ruck and Philip Seymour Hoffman. Once the actors realized they’d be second fiddle to the special effects, they figured they might as well just have fun with it.

“That’s why people liked us so much — because we were so relaxed,” he says. “It wasn’t about us, it's about the thing. When people bring up the movie to me now, they don't talk about the tornadoes. They talk about us, because we were having so much fun.”

He’s forever grateful to have an improvised moment with Hoffman, who died in 2014, immortalized onscreen.

“People laugh at the scene where I'm going, ‘Food, food, food’ with Phil. That's how we greeted each other every day: ‘What's up.’ ‘What's up, brother,’” Whalen says. “I love that I have that on film forever — me and Phil doing our little finger thing.”

As far as taking roles and making them his own, he said it was a lesson he learned the hard way after he flubbed his audition for 1992’s Wayne's World. It was his part to lose — playing the perpetually drunk friend — which was written with him in mind. However, at his audition, he did what he thought the casting director wanted to see instead of delivering his own interpretation of the character.

“What I finally realized was: I'm Sean Whalen. This is what I bring,” he says. “If you want me, great. But if I'm not the guy, I don't really want to do a lame version. I want to do what I think is funny.”

That has led to collaborations with filmmakers to develop his characters and make them unforgettable, regardless of how long or short he’s on screen. For instance, he was supposed to only have one line in 1999’s Never Been Kissed, before getting the chance to develop the part of Merkin with producers Nancy Juvonen and Drew Barrymore, who doubled as the star. (He’d go on to work with them again on Charlie’s Angels, released in 2000.)

“Nancy and Drew said, ‘What would you do?’” Whalen recalls. “I go, I think it's funny that a guy thinks he's the Wolf of Wall Street. He thinks he’s a badass — super-cocky, the spiked hair, the headset — and he’s a copywriter's assistant and he thinks he's the next Tony Robbins. That's funny to me. They go, ‘Do it.’ I got to design my outfit — they got me an Armani suit — and everything I asked for. I also wrote all my lines: ‘Power is powerful.’ ‘This whole office is not feng shui.’”

Not being at the top of the call sheet means Whalen still has to hustle.

“I don't have the luxury of going, ‘I'm going to choose this part or that part,’” he says. “I need to pay bills, just like everybody else. … The main thing is, I just do what I think is funny.”

He’s doing more and more of his own projects in recent years. The father of two started a production company, MSYL, with his wife, Sheena Fink Whalen, whom he married in 2021.

Whalen wrote, directed and starred in the 2024 independent horror-comedy film Crust, which he crowdfunded to make. It’s about a guy in a laundromat who has a sock monster who kills his enemies.

“I got my budget within three days, and then we tripled it,” he says. “People kept giving money. I said, ‘Why are you doing this?’ They said, ‘Because we like you. You've been making us laugh for years. We want you to do bigger parts.’”

Now Whalen’s trying to make Swipe, another horror film about three female slashers.

“I just want a fresh take on everything,” he says. “I can't do normal. That's me and my producing partner, Rebekah Kennedy’s thing. If you know what's going to happen by halfway through, we don't want it. We always want it to be different and weird.”

And he’s ready for more. While Whalen is happy to reminisce about the ’90s, his eyes are on the future.

“I did those movies in my early 30s, and I'm 61 now,” Whalen says. “I want to have my second act. I want to have my Sean Connery [arc] — you know, thin, hot as hell Sean Connery in the ’60s to old, gruff, bearded Sean Connery. He was two completely different guys.”

“That's what I'm looking [forward to],” he continues. “I want someone to come to my table at a [fan] convention and not just go, ‘Oh, Twister, The People Under the Stairs.’ I want them to go, ‘Crust. Swipe’ — my new stuff. That's my real goal. I want to be relevant today — not just in the ’90s.”