In October 2021, Lori Evans Taylor was announced as the new writer for the film. By January 2022, HBO Max revealed it would distribute the movie, with Jon Watts joining as a producer and Taylor co-writing the screenplay with Guy Busick. In July, Reddick mentioned that the new film would differ from the franchise’s usual formula.

In September, Zach Lipovsky and Adam Stein were chosen from over two hundred candidates to direct the film, impressing New Line executives with a creative pitch that included a staged freak accident reminiscent of the franchise’s iconic scenes. In September 2023, Bloody Disgusting reported that Tony Todd would reprise his role as William Bludworth, with the film exploring his character’s backstory.

In March 2024, the cast was announced, including Brec Bassinger, Teo Briones, Kaitlyn Santa Juana, Richard Harmon, Anna Lore, Owen Patrick Joyner, Max Lloyd-Jones, Rya Kihlstedt, and Tinpo Lee in undisclosed roles. Principal photography, originally scheduled for July 31 to October 13, 2023, in Vancouver, British Columbia, was delayed due to the SAG-AFTRA strike. Filming eventually took place from March 4 to May 6, 2024, with Christian Sebaldt as the cinematographer.