Another plot could be Genos getting caught in a cross - fire of a battle between two extremely powerful cosmic entities. His body is severely damaged and despite Saitama's attempts to get him help, his internal systems fail one by one. His death could then lead to Saitama realizing the true fragility of life around him and make him more protective of the remaining heroes.
First, consider the role the OC will play. If it's a partner for Genos, think about their combat abilities. For example, if Genos is mainly a physical fighter, the OC could be a support with long - range attacks or healing powers.
How about Alucard from Hellsing? He is an extremely powerful immortal. In a crossover with Genos, Alucard's centuries - old experiences and his complex relationship with humanity could play off well against Genos' more recent creation as a cyborg. They might start off as adversaries, but then find common ground in their fight against a greater evil. Genos could learn a lot about the nature of immortality from Alucard, who has seen so much over the years.
Female Genos could be developed with a more empathetic side. Since she is a cyborg, she could struggle with understanding human emotions more deeply. Maybe she starts to learn about love and friendship in a different way compared to male Genos. For example, she might be more sensitive to the feelings of other female characters around her.