Lewis was drafted to play for Hawthorn with the seventh selection in the 2004 AFL Draft and made his AFL debut in season 2005.
Lewis was voted Hawthorn's best first-year player in 2005. He was a 2005 nominee for the AFL Rising Star award.
On 11 June 2006 Lewis was accused of spitting on Port Adelaide onballer Kane Cornes. Lewis apologised to Cornes after the incident, in which he spat on Cornes' hand. On 14 June, an AFL inquiry found that it was unclear whether Lewis had accidentally spat on Cornes, while spitting on the ground, or whether his actions were deliberate. the league declined to impose a penalty and investigations officer John Coburn said: "the fact that Cornes' hand was at his side lent weight to Lewis' claim he was intending to spit on the ground."
A Hawthorn vice-captain in 2012, Lewis led the side whilst captain Luke Hodge was sidelined during the early part of the season.
In 2013 Lewis signed a contract extension with the Hawthorn Football Club to ensure he is at the club until the conclusion of the 2015 season.