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Rat King debuted in only the 5th episode of Season 4. They could have easily had him appear again in mid/late Season 4. There were still plenty of fillers being made or he could have appeared in the plot-centric eps with Bishop discovering his clone was still alive.
In Season 5 he could have easily been in one of the two inbetween episodes when they were back in NYC. As I said, the fact that they wanted to make a third Garbageman ep of all things instead of giving Rat King a second episode is mind blowing.
Even in Fast Forward he could have theoretically appeared if you assume Rat King could live for 100 years or something.
Then in BTTS again he could have easily gotten an ep instead of that Serling/toddler Turtles ep, or the dumb Green Mantle superhero ep, etc.
They had more than enough time in every season to give him another ep so that's not an excuse. Also at the end of his first episode he says, "I'll haunt their nightmares for days to come" or something along those lines...yet he never faces the Turtles again. And there was still the Splinter/Rat King meeting they never did where Splinter is injured and Rat King appears as a ghost/hallucination that Nick adapted instead.
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