Tom Tataranowicz had advocated eliminating the Stan Lee intros in the interest of more screen time for the stories. However, it was felt that Stan's vast legion of fans liked seeing him intro the episodes and that not using him could frankly be interpreted as insulting to Stan. Tataranowicz realized that they were right. Thus, they did shorter Stan Lee intros with Stan "green screened" so we could place him against backgrounds from the shows. Using his previous live action experience, Rick Ungar set everything up and Tataranowicz directed Stan through the intros. Stan's energy was and is amazing, and Tataranowicz thought these came out rather well, adding nicely to both the "Iron Man" series.
Initially there was a bit of grief about the new crew wanting Tony Stark to have long, shoulder length hair in Season 2. It was felt that he might look too much like "Conan." It was actually inspired by artist Mark Bright's depiction of Stark from the late 1980s Iron Man comics. Nonetheless, they wanted to distance him from the plethora of clean cut alter egos ala Bruce Wayne, Clark Kent, etc. It also billboarded that this season was different than the previous one. Aesthetically, the idea of an uber-business man with unfashionably long hair also seemed like an ideal way to solidify his character of an outsider who marched to his own drum.
The only piece of Hulk transformation footage not used from the Fantastic Four Hulk episode 2.09 "Nightmare in Green" was the scene at the end when the Hulk changes back into Bruce Banner (episode 2.11 "Hulk Buster").
Instead of the main superhero team being the obvious choice, the Avengers, which was founded by Iron Man, the series went with the short lived team lead by the Scarlet Witch, Force Works. In the comics, Force Works was created after the Avengers East Coast disbanded the Avengers West Coast, which lead to Scarlet Witch, Spider-Woman, Wonder Man and Hawkeye quitting.
In modernizing the Iron Man's origin story, Tony Stark is not injured in a Vietnamese war zone, but in an act of industrial sabotage plotted by Justin Hammer and the Mandarin. Stark was wounded not by a chunk of shrapnel near his heart, but by slivers near his spine, Stark and Yinsen (whose first name is changed from Ho to Wellington) were held captive by the Mandarin, rather than Wong Chu. However the concept of the Iron Man armor keeping Stark alive was in Season 2 with getting Iron Man injured in his chest after taking a direct hit from a missile while attacking Hammer on his own property. He upgraded his armor in order to attempt to heal his chest.
Tony Stark's main armor on the show was the "Mark XI "Modular Armor", which was the suit he was wearing in the mid 90's comics. The first season modified his helmet design to add a traditional mouth slit, but the second season restored the "mouthless" comic book design.
Wonder Man wasn't used in the TV series, as in issue #1 of Force Works, he was killed off. However, he was resurrected in the third volume of the Avengers, hence his appearance in the Avengers TV series.
In the original comics War Machine had various additional weapons such as an automatic Gatling gun and a missile launcher on the shoulders of his armor. The cartoon incarnation omits these due to them being inappropriate for a family-friendly show and instead his armor has more of a resemblance to Iron Man's armor aside from the color difference.
Rainbow Animation Group was chosen to do the animation for the first season because of their proven ability to provide high-quality heroic-type animation and seamlessly integrate all kinds of visual materials. Starting with the second season, Marvel Productions switched animation houses and the series got a new look, feel, and direction. While Fantastic Four (1994) was revamped with John Buscema in mind, the crew did not have another particular artist in mind for "Iron Man". They went for a more graphic and streamlined approach to the series. They kept a bit of WB's Batman: The Animated Series (1992) in mind, mixed it with a little Anime flair and tossed in a touch of a Frank Miller graphic look. They then simplified it to make the details manageable for animation while still maintaining a "cool factor" and stirred it liberally with our teams' own ideas.
During the Mandarin's narration of his origin, he comments that his path will cross with Yinsen's again. This foreshadows episode 1.11 & 1.12 "Origin of Iron Man Part 1 & 2", which details their final meeting (episode 1.07 "Origin of the Mandarin").
The armoured warriors attacked in episode 2.08 "The Armor Wars Part 2", include the Controller, the Beetle (who had previously attacked Stark on "Spider-Man and his Amazing Friends"), Stiltman, Blizzard, Backlash, and the Mandroids.
Matt Frewer voiced the Leader in this series and would continue to voice him on the UPN The Incredible Hulk (1996) animated series, later in 1996. In an online interview, voice director Tom Tataranowicz said, "the casting of the Leader's voice was a satisfying find."