This series was already in development several years earlier, when comics writers had decided to have a wedding for Clark Kent and Lois Lane. The producers of the show wanted to have a similar story line, and did not want to be several years behind the comics in doing it. When it was agreed that the wedding on television would correspond with the wedding in the comics, the comics' writers had to find a new storyline to hold reader's attention in the meantime and give them the readership they had expected the wedding to attract. This led to the now famous "Death of Superman" story.
Dean Cain was the first actor to audition for the part. Series creator Deborah Joy LeVine initially dismissed him as too young, telling her casting director they were looking for SuperMAN, not SuperBOY.
Gerard Christopher auditioned for the role of Clark Kent/Superman, and was chosen by the casting director. However, when the casting director subsequently read Christopher's resume and discovered that he had previously starred as Clark Kent/ Superboy in Superboy (1988), he immediately dismissed Christopher. According to Christopher, the man told him, "you've done this already!"
Early on in season 1, Lex Luthor attempts to test the abilities of Superman. He questions his associates and remarks that amongst other things Superman could be "faster than a speeding bullet, more powerful then a locomotive able to leap tall buildings in a single bound". These are the exact words that began Max Fleischer's short Superman cartoons made during WWII.
One of the early villains describes Superman as the advance guard prior to an alien invasion. He also wonders whether Superman has any telepathic powers. In the very first story featuring the character bestowed with the name "The Superman", Superman was an evil advance guard with special telepathic powers.
According to Executive Producer Brad Buckner, the baby that Lois and Clark found on their doorstep in the series finale was supposed to be Kryptonian royalty. Had they gone to a season five, the storyline was supposed to be Lois and Clark protecting the baby from potential assassins.
Series creator Deborah Joy LeVine and her writing team were dismissed after the first season. New producer, Robert Singer, was brought in with the task of focusing the show more on action and the romance between Lois and Clark.