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Eggman falls immediately into the superheavy category, but I think his Egg Walker mech would distinguish himself nicely and as Gwen addressed before provide a dominating trap-centric style of gameplay that is more or less untapped.
Metal Sonic may be worth thinking about too, or
Shadow if we're being a bit loose with the boss label and dipping more into general rival territory (after all I kept Meta Knight around).
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Porky obviously, although I'd be a little concerned about how his mech-based moveset could overlap with the aforementioned Eggman and Bowser Jr who is already in. Probably best not to focus on one archetype too heavily, but I think his more beastly spider mech design would make him stand out for sure. Probably best to think of it less like a mech and more like a giant robotic bug.
- Porky is Lucas' big bad too, but
Masked Man would be neat and offer some more weight-class variety. Probably a bit comparable to Meta Knight as a lighter swordfighter who's quick in the air, plus being a dedicated gunner type with some lightning magic... I think he'd be great.
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Captain Syrup! Not only does she have obvious and refreshing moveset potential through her role as a pirate and provides us with another midweight, but she also gives us some well needed female villain representation. Cannons, sabers, treasure chests, a genie lamp... You could do a lot here.
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Dr. Coyle too - long-ranged fighter who can float around but is probably among the lightest characters in the game to compensate. Come to think of it with the prevalence of big slow powerhouse characters she would probably dominate LOL.
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Medusa? Viridi sorta? Of course you could go with Hades also, but I'd opt for a more staff based / magic based female antagonist for variety sake. Medusa would probably play as a sort of mirror to Palutena in some ways while Viridi would be more of a summoner character directing the Forces of Nature and sprouting plants and vines and ****. I'd opt for Viridi myself but this is another case where you could debate whether or not she's technically a villain.
- One of the weirdest character choices that I actually want to see in Smash is a
Bulborb. They're just so funny. Poke opponents with your eyeballs, lick them or gulp them up, lay eggs and create little baby Bulborbs to assist you... a more out there pick but definitely something new.
- I think
M. Bison is a bit too iconic to ignore. I feel like if Ganon got redone he may share some properties with Bison, but there's still more than enough here to make him stand out and I mean... he's M. Bison.
Gil would also be pretty badass.
- Lots of options.
King Hippo would be my default pick but maybe for variety sake we could go with
Mr. Sandman and then
Glass Joe as a joke character. Any of these choices would be great and could focus on a more dedicated, traditional boxing style in contrast with the weird magic and unconventional antics provided by the others.
Shoutouts to
Samurai Goroh I think he would be a lot of fun.
Black Knight should probably be here too. Just burnt myself out for now.