Capt. Picard and the crew use the Captain's Yacht to travel to the surface of the Ba'ku Homeworld. This is the only instance in either Star Trek: The Next Generation (1987) or the movies in which such a vessel is ever used, although at one point during Star Trek: The Next Generation: Samaritan Snare (1989), it was briefly suggested that the Captain's Yacht for the Enterprise-D be used to transport Captain Picard to Starbase 515 for immediate heart surgery. On that occasion the producers decided to use a traditional shuttlecraft instead, to cut cost.
When Data is malfunctioning, Picard gets him to recite Sir W.S. Gilbert and Sir Arthur Sullivan's "H.M.S. Pinafore". In the Isaac Asimov story "Runaround" a malfunctioning robot recites Gilbert and Sullivan while evading capture by his human masters. Much of Data's character is taken from Asimov's writings (such as Data's "Positronic Net", adapted from Asimov's "Positronic" brains).
Following the confirmation what the climax would be for the 6th season of Star Trek: Deep Space Nine (1993), Michael Piller added a couple of lines to the film acknowledging the tragic climax and the impact it had on Worf. Rick Berman eventually overruled this, arguing that this film would confuse film audience members who didn't follow the show regularly.
On the VHS Commentary (which appears at the end of the VHS copy of the movie), Actor/Director Jonathan Frakes says that for the scene where Ru'afo (F. Murray Abraham) has his skin folded over his head, Producer Rick Berman and several of the make-up artists had visited a plastic surgery clinic and watched surgeries being performed to get ideas for that particular scene.
According to a leaked manuscript, Fade In: The Writing Of Star Trek: Insurrection (written by Michael Piller years before his death, and never released because of studio concerns about the content of said manuscript), initial concepts for the film were far removed from the final product. The first script treatment (called Star Trek: Stardust) involved Picard and a fellow cadet named Hugh Duffy (who were friends at Starfleet Academy) meeting up after almost three decades because of different circumstances. Duffy has become a renegade who has tried to provoke a war between the Federation and the Romulan Empire, and Picard must travel to the Neutral Zone to bring him back. Picard eventually finds Duffy and risks his career to help the other officer thwart a plan by the Romulans to take over a planet housing "the fountain of youth". At the end, Picard gets arrested (and stripped of his rank) by Starfleet due to his actions during the film. The plot was similar to Heart of Darkness, and featured numerous references to various episodes of Star Trek: The Next Generation (1987).
Patrick Stewart wanted his lifelong friend Brian Blessed to play Admiral Dougherty. Blessed did over 800 hours of astronaut training at Star City in Russia, and remains the number one civilian on the wait list for the International Space Station.
This is the first time in over ten years, since the end of season one of Star Trek: The Next Generation (1987), where we see Commander Riker without his beard. It's the first time, that he is seen both with and without the beard and the last time to see him beardless. It has been known that Jonathan Frakes wanted to do the shaven Riker from Female letter requests.
Many of the shots used in the Teaser Trailer, such as when the crew are grabbing the phaser rifles, and when the Enterprise E is making a turn to engage, and when other ships are lining up to fight, the Enterprise is firing quantum torpedoes, are shots used for Star Trek: First Contact (1996). There is also a shot of the Enterprise-D from Star Trek Generations during this trailer, from the scene in that movie when it is being attacked.
Titles considered for this ninth entry in the Star Trek franchise included "Millennium", "Nemesis" (later co-opted for the next film in the series), "Pathfinder", "Past and Future", "Transcendance", "Rebellion", "Stardust" and just plain old "IX".
The Enterprise-E crew quarters, transporter room, and sickbay were redressed forms of the sets used on Star Trek: Voyager (1995). The quarters had originally been built for Star Trek: The Next Generation (1987), and portions of sickbay date back to Star Trek: The Motion Picture (1979). In addition, the bay where Picard and the Baku are held by the Son'a, is a redress of Voyager's cargo bay, and the shuttlecraft used by Picard and Worf is a redress of the Runabout set from Star Trek: Deep Space Nine (1993). Data's shuttle interior in this film is a redress of the Voyager shuttlecraft interior.
Anthony Zerbe originally auditioned for the role of Ru'afo and was considered to be the best choice for it.However, the production team decided instead to cast him in the role of Admiral Matthew Dougherty. During Zerbe's audition, instead of reading the lines provided, he recited Dante's Inferno before seamlessly moving into the script. Jonathan Frakes and the producers unanimously decided to award him the part of Dougherty.
The trivia items below may give away important plot points.
In the original ending to the film Ad'har Ru'afo was to escape in a craft that fell into the rings that surrounded the planet, where he would get younger and younger. After it was changed the director sent F. Murray Abraham a tape of the original ending to see how it had turned out anyway.
Picard was originally going to kill Data in the film, a decision fully supported by Brent Spiner, who felt he was getting too old to play the character. This was vetoed by Patrick Stewart. Spiner's script came with a note reading "Better luck next time." See the next film Star Trek: Nemesis (2002).
In a scene of the film, Worf wakes up from a nightmare, when Picard calls him on the intercom. In the back story, Worf had a nightmare about a tragedy he suffered in Star Trek: Deep Space Nine (1993), which took place before this film. Worf's Trill wife Lt. Commander Jadzia Dax was murdered by Gul Dukat.
The film bare a plot similarity with Star Trek: Deep Space Nine: Battle Lines (1993). Which in that episode, Commander Sisko, Major Kira and Dr. Bashir discover that the Ennis and the Nol-Ennis are being regenerated by a alien nanotechnology in the environment of the moon which is their penal colony. In this film, The Enterprise crew discover that on the Bak'ku planet, the Ba'ku can regenerate due to the planet's regenerative radiation.