Wow...this is a toughie...
I must say that its a tie between Seymour (LSOH) and Archibald (Secret Garden)
Seymour is a character that I just connected to the most. From his feeling of not being good enough and having the need to please others right down to his clumsiness. The emotional journey and his character arc is also really nice and even though its a "lighter" musical it still has a lot of dark moments especially in terms of Seymour's physiological state of mind. And plus, the score is a one of the most enjoyable to sing. My voice at the time of playing him (14 years old) was in that phase of just getting out of the huge voice change (went from soprano to tenor in a matter of weeks haha) and I was starting to get a lot of control and power behind it. And I was also just starting to get voice lessons and we went through the logistics of "belting" in a safe manner...so to be able to put those techniques in practice while singing "Skid Row" "Get It" "Suddenly Seymour" and "The Meek Shall Inherit" was something I will never forget.
Archibald however is a completely different persona that was a total departure from other characters I played. This role I played recently and it's by far the most challenging in terms of character development and vocals. This is a full 4 years since I played Seymour so I have grown since then as an actor but nothing quite prepares you for the beast that is "The Secret Garden." I really did not want to make Archie a one dimensional pitiful human being like other Archie's I had seen. I wanted him to have a deep pain that extended past Lily's death. Lily was the only one who loved him regardless of the hunch...so when she died, so did his feeling of ever being loved and accepted. And he did not want Colin to experience this same pain (hence the bed ridding he did to him.)
Vocally, this role had some pretty high notes...but being a tenor that wasnt the issue. The issue was to make them soft and not overbearing in the songs that were more quieter (such as "How Could I Know?" "Someone Crying" and the end of "Race You To the Top of the Morning") so I had to really put the mixing side of my training to do that and that took A LONG time to handle. However "Lily's Eyes" "Quartet" and "A Bit of Earth" I could let the belting ensue :)
Sorry if that was long...I really like to delve into characters haha
"Life in theater is give and take...but you need to be ready to give more then you take..."
Im really proud of that one. Never forget it. 
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