How could I possibly not notice that?

I originally had Hardcase's voice changing in episode 30 as a sort of escape hatch, but I wrote 29 in a way that could easily switch actors there instead, which I did when John Gantz quit.

He said he'd continue recording the remaining scripts, but a couple months later nothing had happened, so I decided I had to cast a third interim hardcase.

The episode 29 and 30 hardcase had already recorded by then, and the story as recorded required that he be different from the episode 25 voice, so it was easier to rewrite episodes 22 and 23 a little bit to talk about a new voice there.

And finally, I made some little changes to the episode 30 script to have Dr. Tenet explain it as a prior Hardcase voice that died.

What's the process of making Beyond Awakening like? How does it work?

It starts with a lot of writing.

I've written most, but not quite all, of each season before the Kickstarters.