Sylvan (movie)/Development

Production of the film began in 1994 with, , and RKO-Columbia TriStar Ventures Latin America producing it. Filming took place in England, with the scenes at King Charles' castle being filmed in Bodiam Castle in East Sussex, and other scenes filmed at BBC Television Centre in London and in the village of West Kington. According to Antoni D'Ocon, who was the film's producer, the Robertsbridge village council tried to get the shoot at Bodiam closed down when villagers mistook the actors in their makeup and suits for creatures from "the underworld", but the producers managed to film the scenes successfully.

Dick Smith was the film's makeup artist. He built prosthetic makeup pieces and puppets for the film, the biggest of the puppets being King Charles.

British-Australian actor Dominic Purcell was cast as Sylvan. The makeup "took forever to apply" said Dominic in a 2009 interview. Dominic had the Sylvan prosthetic (complete with a tuft of blonde hair) applied to his face by a co-worker of Dick. The rest of the Sylvan body was a costume, complete with ginger-colored fur and a tail. Sylvan's yipping (heard in some scenes) was performed by voice actor Frank Welker.

King Charles was built as a puppet voiced by Don Marty, best known for playing Santa Claus in the 1938 Christmas b-movie The Christmas That Almost Wasn't But Then Was.

The Death Warrior was played by Rick May in a suit made from cardboard and plastic, painted to look metallic. The Death Warrior's voice was dubbed by Dennis Bateman.

Filipino television star Angelika Dela Cruz played Princess Diana, and wore prosthetic makeup and various dresses and costumes.

Evila was played by Samantha Newark, wearing prosthetic makeup and a costume.

David Lee Roth played Linmer through prosthetic makeup.

The movie took a entire month to film, with a large budget.