Chao graduated from Stanford University with a degree in Mechanical Engineering. He worked for a short time as the mascot for the Chicago Bulls and has competed on American Gladiators.
His filmography includes a minor recurring role as Danny Wong on the TV show The Division (with Ping Wu). He has also had minor guest roles on several other TV shows, including The Event (with Ian Anthony Dale, Bill Smitrovich, and Zeljko Ivanek), Gilmore Girls and Frasier. He has had roles in many films, including Mad Cowgirl, Goldfish, and Miss Congeniality 2: Armed & Fabulous (with Regina King).