Flight scenes were filmed in replica B-17s using technology known as The Volume (used on The Mandalorian (2019)). The B-17s were suspended 50 ft in the air on a gimbal inside a 360-degree stage of seamless LED panel screens and ceiling. Actors could therefore react to flak explosions, crashes and planes flying in real time as the gimbal simultaneously reacted to scenarios.
Three B-17 replicas were built from scratch for filming use. 2 were exact replicas, the other was slightly larger to allow more room for camera crew to film certain angles of the plane.
Austin Butler watched footage of the real-life Cleven who was interviewed about his time as a bomber pilot when he was in his 80s. The footage helped Austin learn Cleven's speaking cadence and sense of humour.
Some of the 100th Bomb Group Veterans who attended the Masters of the Air (2024) premiere said they were holding on and living just to be able to watch the series. John "Lucky" Luckadoo, one of the last living members of the group said at the premiere, watching Masters of the Air (2024) made him feel like he had just flown another mission.
The 100th Bomb Group became known as "The Bloody 100th" due to the heavy volume of losses it incurred in combat missions and minute percentage of survival.