The suit for Nemesis weighed in excess of 60 pounds. Stuntman Matthew G. Taylor could only stay in it for periods of up to 15 minutes before it got too hot.
Milla Jovovich was disappointed by this film. She said that the studio wanted more action and explosions and that the story was swept under the rug.
To prepare for her role, Sienna Guillory actually bought a PlayStation 1 Console and a copy of the game to study the Jill Valentine character. She also based her movements of Jill by watching the way Jill moved in the game Biohazard 3: Last Escape (1999).
As in the first film, the zombies were mainly all professional dancers. They attended an "undead boot camp" where two of the cardinal rules were no dragging feet and no outstretched arms.
The trailer for this film was one of the most watched on the Internet, with 8.5 million downloads from November 2003 to May 2004.
Alexander Witt: Near the end of the film, the film's director plays the Umbrella sniper who tries to shoot down Carlos but gets knocked out by Alice.