He subsequently moved to the U.S. and began appearing in American films; some of his earlier roles there included the 1992 film, The Mambo Kings, as well as a supporting role in the Oscar-winning 1993 film, Philadelphia. He appeared in several major Hollywood releases in 1995, including a starring role in the Robert Rodriguez-directed film, Desperado. In 1996, he starred alongside Madonna in Evita, an adaptation of the musical by Andrew Lloyd Webber and Tim Rice in which he played the narrator, Che, a role originally played on Broadway by Mandy Patinkin. He also received critical praise for his role as the fictional Mexican masked swordsman, Zorro in the 1998 film The Mask of Zorro, for which he was the first Spanish actor to portray the character after over 80 years since Zorro's creation.

He has also frequently collaborated with Robert Rodriguez who cast him in the Spy Kids film trilogy and the final installment in the "Mariachi" trilogy (in which he appeared with Johnny Dep