He most notably collaborated with acclaimed filmmaker Guillermo del Toro, appearing in the films Mimic (1997), Hellboy (2004), Pan's Labyrinth (2006), Hellboy II: The Golden Army (2008), Crimson Peak (2015), and The Shape of Water (2017).

Jones' other roles include Hocus Pocus (1993), Tank Girl (1995), The Cabinet of Dr. Caligari (2005), Fantastic Four: Rise of the Silver Surfer (2007), Absentia (2011), Ouija: Origin of Evil (2016), and The Bye Bye Man (2017). He has also appeared in the science fiction series Falling Skies (2013–15) and del Toro's horror series The Strain (2014–16). Since 2017, he has portrayed Commander Saru in the science fiction series Star Trek: Discovery.

Jones started his career in the television and movie industry as a 1980s ad character, "Mac Tonight". He worked as a contortionist, saying, "You'd be surprised how many times that comes into play in commercials. They'll want somebody to hold a box of Tide funny or something. I once squished into a box for a commercial for relaxed fit jeans".

Although known mostly for his work under prosthetic makeup, such as the zombie Billy Butcherson in the Walt Disney Pictures Halloween film Hocus Pocus, or the lead spy Morlock in the 2002 remake of the 1960 film The Time Machine, he has also performed without prosthetics in such films as Adaptation, Mystery Men, and Batman Returns.

He played Abe Sapien in Hellboy, although the voice was performed by an uncredited David Hyde Pierce. Explaining the challenge of working so often in rubber suits and prosthetics, he notes, "I have to make that a part of my being and my physicality and again, acting is a full body experience and that's a part of it when you're doing a costumed character."

In 2005, he worked again with Mexican director Guillermo del Toro, starring as the Faun in del Toro's multiple-Academy Award-winning Spanish-language fantasy/horror project Pan's Labyrinth. He also has a secondary role in the film as the Pale Man, a gruesome creature with a penchant for eating children.

In 2006, Jones appeared in the feature films The Benchwarmers and Lady in the Water, and reprised his role as Abe Sapien by voicing the character in the new Hellboy Animated television project, recording two 75-minute animated films.

In June 2007, he appeared in Fantastic Four: Rise of the Silver Surfer as the Silver Surfer (though Laurence Fishburne provided the character's voice). He reprised his role as Abe Sapien in Hellboy II: The Golden Army, once more under the direction of del Toro, for which he provided both the voice and body performance. He played two other roles in the film: the Angel of Death and the Chamberlain, both under heavy prosthetics. In 2009, del Toro announced on BBC Radio that Jones would be playing the monster in his upcoming version of Frankenstein.

According to en.wiki.org