WITH THE MARVEL Cinematic Universe grossing over $31 billion worldwide and dominating the superhero genre in the mainstream for three decades now, it’s easy to forget that before Iron Man made his debut in 1963, a DC superhero had already been doing his thing for a full quarter-century. And not just any superhero — the superhero. The character who set the tone and established the standard for everything that followed.
Of course, we’re talking about the Last Son of Krypton, the Man of Steel — Superman.
Depending on who — and how — you count, Supes and his alter ego, Clark Kent, have been portrayed on screen about half a dozen times since the mid-20th century. Each actor has drawn attention for the physicality they brought to the role – never more so than in his most recent incarnations.
As James Gunn’s latest take on the Superman mythos hits the big screen, with David Corenswet donning the cape as the Big Blue Boy Scout, we thought it was the perfect time to look back at how each actor has tackled the daunting task of filling out those iconic blue tights to portray arguably the most important hero of our age.
George Reeves
Starred in Adventures of Superman from 1952-1958. Unlike modern superhero prep, Reeves didn’t undergo a drastic physical transformation. In the 1950s, actors weren’t expected to boast bodybuilder physiques. Reeves, a former boxer and athlete, maintained a naturally solid build through regular activity rather than specialised training. Interestingly, his costume was made from thick wool, which both added bulk and hid any lack of extreme muscular definition. Anecdotes suggest he sometimes wore padding for a more heroic silhouette, especially in later seasons as his weight fluctuated.
Christopher Reeve
For many, Reeve — who tackled multiple films in the role from 1978-1987 — represents the pinnacle of on-screen Superman. Reeve started as a slim stage actor. To fill out Superman’s iconic suit, he trained with bodybuilder David Prowse (the man inside Darth Vader’s costume). Reeve reportedly gained about 15 kg of muscle, transforming his physique while still maintaining a graceful, athletic look. Allegedly, Reeve enjoyed the process so much that he continued lifting weights and gaining size. Superman II was filmed back-to-back with the original film but was plagued with reshoots and director changes — you can visibly discern the scenes which were shot much later on, as Reeve continued to stack on muscle.
Dean Cain
Starring in the TV series Lois & Clark from 1993–1997, Cain came to Superman already fit from his days as a college football player. Instead of extreme bulking, he easily maintained his physique with regular weight training and cardio. His suit was lightly padded but relied mostly on his natural build. Costume designers even had to adjust the suit for the size of his quads.
Brandon Routh
Routh starred in 2006’s Superman Returns, a spiritual successor and love letter to the earlier films. He worked with personal trainer Gunnar Peterson to add size and fill out a more modern version of the suit. Routh is said to have added roughly 10 kg of muscle, focusing on traditional weightlifting, core strength, and a high-protein diet. His suit was built with minimal padding, relying heavily on his actual build.
Routh portrayed a version of the character over a decade later during the CW’s Crisis on Infinite Earths crossover event. Clearly he’d kept up the training as despite now being in his 40s, the star was visibly more stacked portraying an older version of Clark Kent, based on the Kingdom Come comic series.
Tom Welling
Welling had the longest stint as Kal-El, playing Clark Kent in Smallville from 2001 to 2011. He began the series already in excellent shape, thanks to a background in modelling and sports. As Smallville progressed — particularly in the later seasons, where Clark’s physicality became more prominent — Welling maintained a consistent training routine. He worked with trainers on a mix of bodybuilding, functional strength, and agility exercises to stay lean and camera-ready. However, he deliberately avoided going “full superhero bulk” to keep Clark relatable as a young man still growing into his powers.
Welling never actually donned the iconic Superman suit until the series finale, where he wore the costume from Routh’s portrayal. No word on whether any alterations were needed — so we guess we’ll never know who filled it out better…
Henry Cavill
In a mixture of feature films and cameos from 2013–2021, Cavill is perhaps the most infamously jacked Superman. Cavill trained with Mark Twight and his team, previously known for preparing the cast of 300. His regime involved intense metabolic circuits combined with more traditional high-volume bodybuilding, and a high-calorie diet to fuel muscle growth, recovery, and an intense shooting schedule. Cavill gained a lot of size for Man of Steel, arguably redefining forever what it takes to portray Supes on the big screen.
Tyler Hoechlin
Hoechlin debuted as Superman in the TV series Supergirl in 2016 before leading his own show in Superman & Lois. Already athletic from his baseball background and previous roles, he worked with trainer David Buer to further refine his physique, focusing on functional strength and lean muscle rather than sheer bulk. Unlike previous Supermen, Hoechlin’s portrayal emphasises a relatable, family-oriented Clark Kent, balancing superhero action with domestic life. His suit features some light padding but largely showcases his natural build. Although a slightly lither physique than Cavill, Hoechline clearly puts in some serious training.
David Corenswet
Our Superman ascendant, Corenswet worked with trainer Paolo Mascitti ahead of the 2025 release of James Gunn’s new take on the character. Mascitti says Corenswet packed on around 18 kg in his prep for the role, following a bodybuilding-style push/pull/legs split, but that he had dropped some of this weight before filming as he began reducing his body fat. At 6’4”, Corenswet cuts an impressive shape in a newly designed version of the costume, and although the inevitable comparisons to Cavill have been pretty positive, Corenswet’s suit doesn’t seem to visually accentuate his musculature as much — possibly to play into Gunn’s more light-hearted take on the character.
This article originally appeared on Men’s Health UK.
Related:
David Corenswet’s complete ‘Superman’ workout routine and diet plan
