Star Trek: Strange New Worlds has delivered one of the franchise's most delightfully bizarre episodes yet with Season 4, Episode 5, "Level-Five Transporter Accident." The episode, teased at SDCC 2025, goes full Muppets with Jim Henson Company puppets, slapstick comedy, and even a hint of romance. But pulling it off was no small feat—it took 14 puppeteers, hundreds of hours of planning, and a complete rebuild of the Enterprise bridge's captain's chair.
In an exclusive interview, co-showrunners Henry Alonso Meyers and Akiva Goldsman broke down the episode's creation. Meyers, who co-wrote the script with Dana Horgan, explained that the team wanted to match the ambition of their earlier musical episode. "We couldn't just half do it," he said. "We really needed to rise up and try to make the best possible version of it." The transporter accident premise—a classic Trek trope they'd never tackled—became the perfect vehicle for the puppet chaos.
The logistics were staggering. The production reached out to the Jim Henson Company early in the process, and director Jordan Canning spent months walking through sets to plan shots. Fourteen puppeteers worked on set, and the captain's chair had to be rebuilt to accommodate one of them. "Our sets are great and are weirdly well suited towards puppeteering," Meyers noted, adding that the team's preparation made the puppets feel spontaneous.
For fans of the franchise, the episode is a love letter to both Star Trek and Muppet enthusiasts. "There is a median between people who love Muppets and people who love Star Trek," Meyers said. The goal was to create something that appeals to longtime Trekkies while also drawing in newcomers—a balance the show has struck throughout its run.
Beyond the puppets, Goldsman teased the Season 4 finale, "Tomorrow's Enterprise," which nods to the classic Next Generation episode "Yesterday's Enterprise." He called it a "timey-wimey" adventure, promising an emotional send-off for the six-episode final season, which is expected to air next year. "We wanted to go out on an emotional note," he said.
For those who haven't seen the episode yet, the puppets allow for gags that live-action actors could never pull off—like a suitless spacewalk that's both hilarious and surprisingly touching. Meyers confirmed that nearly every wild idea made it into the final cut, a testament to the team's dedication.
As Strange New Worlds heads toward its conclusion, this puppet episode stands as a bold experiment that could only happen in the Star Trek universe. Whether you're a die-hard fan or just curious about the Muppet crossover, this is one adventure you won't want to miss. And if you're hungry for more behind-the-scenes looks, check out our exclusive clip of the Enterprise crew as puppets.
With the final season on the horizon, Meyers and Goldsman are clearly aiming to leave a lasting impression. "If this is the last season, because we never know, what are the things that you really, really, really wish you'd tried?" Meyers said. This episode answers that question with a resounding, puppet-fueled yes.
