Building 75 Costumes for a 25 Minute Episode with Valerie Klarich - Stuart Fails to Save the Universe

Talking Big Bang Theory spinoffs to superhero suits and 3D-printed icicles — costume design 'behind the seams' at its best!

Costume designer Valerie Klarich returns to Voice of Costume to unpack her wild ride designing "Stuart Fails to Save the Universe," the HBO Max spinoff of The Big Bang Theory. Valerie shares how a decade-long friendship with Lauren Lapkus (Orange Is the New Black) led to the job of a lifetime, and how she battled imposter syndrome before landing it. She dives deep into the creative process behind dressing familiar characters across wildly different dimensions — post-apocalyptic wastelands, 1950s primitive worlds, and comic-book superhero universes — all while honoring original designer Mary Quigley's iconic Big Bang Theory looks for nostalgic fans.

Hear how Valerie built roughly 75 costumes for a single 25-minute episode, used 3D body scanning and fabric printing to create Mr. Freeze's icicle-textured suit, and paid tribute to classic Stuart Bloom with an exact plaid-and-robot-tee callback. Plus, behind-the-scenes stories of dressing guest stars Penn & Teller, Weird Al, and Wil Wheaton (including his surprise Star Trek reunion with director Jonathan Franks!).

Valerie also opens up about leading a 17-person costume department with collaboration and humor at its core, and teases what's ahead for season two. 

A must-listen for costume design lovers, Big Bang Theory fans, TV production nerds, and anyone curious about the magic of superhero costume creation.