Hm, I’m pretty sure Wally Cox has everyone beat, here.
Why’s that?
I was hoping it would be Andy Serkis.
Simon Pegg;
Shaun of the Dead
James Montgomery Scott
Nick Angel (Hot Fuzz)
The Editor (Dr Who)
Unkar Plutt (SW)
Also I’ve seen a a 3D printed Gary King
…and a Dengar, but the OP said no voiceovers.
He doesn’t have a Johnny Mnemonic or Klaatu action figure?
What you will find when you google Klaatu action figure is that there is a minor Star Wars character named Klaatu. He was a guard on Jaba’s ship who appeared in one scene and had no lines. This being Star Wars he has three different action figures.
So what?
It obviously does not apply.
From the OP:
“Multiple versions of the same character don’t count either.”
Man, I don’t miss my obsessive SW figure collecting days. OK, maybe a little. 
I believe the characters of Klaatu, Barada, and Nikto all appeared in Jabba’s Palace. I think characters of their species also reappeared in episodes of The Mandalorian.
Does Lucas also have four characters named Eep, Opp, Ork, and Ah-Ah?
Well… the creatures that they ride in The Mandalorian are called Blerrgs. What has become clear when they first made action figures for Star Wars is that the technicians and artists who designed and built them were just playing around, and weren’t really considering them beyond their immediate role in the story. Many character names were just puns or anagrams. It was only when they started making toys and writing novels that they needed to nail some lore down to justify these arbitrary baby-sounds.
I think you could make a valid argument between including Frozone and excluding Groot(Vin Diesel) or Rocket Raccoon(Bradley Cooper). A live action Incredibles could be worth making, and you’d definitely want Sam Jackson to play frozone