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It’s always difficult to say goodbye to new friends, but it was especially tough for Ari Millen while filming the new season of “Orphan Black.”

The Canadian actor plays at least four Project Castor clones in the BBC America hit, which aired its second episode of Season 3 on April 25. [Spoilers ahead!] In “Transitory Sacrifices of Crisis,” clone Rudy was forced to sacrifice his brother, Seth.

Ari Millen

Rudy (Ari Millen) consoles his clone brother Seth as he dies in “Orphan Black.” (BBC American)

“I was just getting to know who Seth was and starting to have a lot of fun,” Millen said during an interview April 25 at the Chicago Comic and Entertainment Expo. “Had he survived, I think he might have been my favorite clone.”

Although it was a sad farewell so quickly after the whirlwind of creating his clone characters, Millen said the “mercy killing” helped him learn more about Rudy, the most psycho of the brothers. In the scene, Seth “glitches” so badly while they are on a mission that Rudy decides he has to put his brother out of his misery.

“It’s all right. I’m here, brother,” Rudy says to Seth as the latter dies. “Don’t hold on. Go easy. I love you.”

Miller said he wanted the scene to show that Rudy is much more than a crazed killing machine who felt like the Castor clones were “playing a game” with the LEDA clones played by Tatiana Maslany.

He nailed it.

In just two episodes, the actor was able to portray such a strong, loving bond between the brothers that the scene was surprisingly moving.

The clone-on-clone killing also motivates Rudy going forward into the season, Millen said.

“It was a pivotal shift for Rudy at that point,” he said.

Earlier in the episode, Rudy and Seth share more than their genetics when Rudy picks up a random woman at a bar and brings her to his hotel room. She sits back on the bed with Rudy, but when she opens her eyes Seth is right beside his brother.

Millen also talked about having a threesome with himself in the episode, saying “I was nervous about getting naked in front of myself.”

He and co-creator John Fawcett, who directed the episode, talk about filming the threesome scene and the Seth death scene in the video above. In the video below, co-star Dylan Bruce discusses another highly anticipated scene from the episode: His character, Paul Dierdan, confronts Cal (Michiel Huisman). Bruce called it the meeting of clone Sarah’s “boy toys.”

Click the links below for more “Orphan Black.”

Ari Millen multiplied his fun.

Tatiana Maslany: Cool clone scenes ahead.

“Orphan Black” videos on my YouTube page.