After years away from the small screen, Emmerdale fans were left reeling as Robert Sugden made a shocking return to the village in a jaw-dropping twist. Played by Ryan Hawley, Robert’s comeback was one of the best-kept secrets in the soap world—until now. In a candid interview, Hawley opens up about how the return was planned, the secrecy behind the scenes, and what’s in store for his character, Robert, as he reenters a dramatically altered landscape.
Robert’s reappearance was nothing short of explosive. Viewers last saw him being sent to prison for killing the man who assaulted his sister Victoria. His sentence was 14 years, but he’s been released after just six. When asked how he managed to serve less than half his time, Hawley jokingly referenced The Shawshank Redemption, quipping that Robert “chiseled his way out with a rock.” It was this kind of unexpected humor that underlined how surreal the comeback felt even for the actor himself.
So how did the show pull off such a surprise in an era of constant social media leaks? Hawley revealed the extraordinary measures taken to keep his return under wraps. Everything from scripts to on-set logistics was executed with precision. He was picked up daily by a private driver named Howard and entered the studio through a hidden entrance so that lurking fans and even some cast members wouldn’t suspect anything. In scripts, his character was listed under the code name “Marco” to avoid spoilers. Cast members on set would even ask, “Who’s Marco?” without realizing it was Robert himself making a stealthy return.
All of this secrecy paid off. The return was met with gasps from fans who had no idea it was coming. “It was the reaction we wanted,” Hawley said, clearly pleased with the reception. He also gave credit to the behind-the-scenes staff who rarely get acknowledged, emphasizing that many people worked tirelessly to make the moment as impactful as it was.
Returning to the show felt like coming home, according to Hawley. His first scenes were filmed during a wedding sequence that brought together much of the main cast, including Kane and Paddy. Seeing so many familiar faces again was deeply emotional for him. The bond between cast members is like family, he explained, which made both his departure years ago and his return now particularly poignant. “It was hard to go. You make the decision and it’s emotional. Then six years go by, and coming back—it felt amazing.”
During his time away from Emmerdale, Hawley didn’t exactly vanish. He appeared in shows like Casualty and spent a significant period in Brazil, where his wife is from. They took the opportunity to spend a year abroad for maternity leave, soaking in time with their family. Though Emmerdale had approached him several times about returning, the timing hadn’t been right—until now. With the stars aligned and a compelling storyline in place, Hawley agreed to rejoin the cast.
As for what’s next in the plot? Buckle up. Robert’s return is far from a casual visit. He’s back for one reason: to win Aaron back. But things aren’t so simple this time around. Aaron has moved on with none other than Robert’s half-brother, John—Jack Sugden’s long-lost son. The emotional stakes are through the roof, and Robert is entering a deeply hostile environment. The rest of the village is far from welcoming. As Hawley put it, “He’s got a lot of bridges to mend.”
The drama is already heating up. In a teaser for the next episode, tensions escalate between Robert and John. What starts as a tense confrontation rapidly unravels into threats, accusations, and even physical danger. “The only thing that needs ending is you,” John hisses at Robert, promising viewers a clash of titans that could reshape the dynamics of the entire show.
Is Robert back for good, or is this just a fleeting reappearance? According to Hawley, it’s indefinite—for now. There’s a major story arc in motion that will unfold through the end of the year. He teased future showdowns, emotional turmoil, and a potential reckoning for “John the baddy,” as some fans have dubbed him. But he also cautioned that the road ahead for Robert is anything but smooth. “There are a lot of obstacles to overcome before any of that can happen,” he said cryptically, keeping fans guessing about what twists lie ahead.
Fan response to Robert’s return has been overwhelming. The legendary “Robron” pairing (Robert + Aaron) still has a loyal following, and social media lit up the moment Robert reappeared. Hawley himself was on a train during the broadcast and didn’t catch all of the real-time reactions, but he’s seen the outpouring of excitement since. From casual viewers to die-hard fans—and even the production staff—everyone seems thrilled to have Robert back in the mix.
