Geneviève Bujold was originally cast as Captain Elizabeth Janeway but left after only two days of filming the pilot because she felt uncomfortable with the demanding TV production process, leading to Kate Mulgrew taking over the role.

Kate Mulgrew, who replaced Bujold, proposed renaming the character from Elizabeth to Kathryn Janeway.

Robert Duncan McNeill had previously played Nicholas Locarno in The Next Generation episode 'The First Duty'; producers initially wanted Locarno to return for Voyager but changed him into a new character, Tom Paris, though casting notes still asked for 'a Robert Duncan McNeill type,' which his own agent recognized.

Robert Picardo originally auditioned for the role of Neelix but lost it to Ethan Phillips; he joked that missing out saved him '6,000 hours' in the makeup chair, and he was instead encouraged to audition for the role of the Doctor, which he won.

Robert Picardo secured the role of the Doctor by improvising an extra line during his pilot audition—'I believe someone has failed to terminate my program' and 'I'm a doctor, not a nightlight,' a nod to Leonard McCoy's catchphrase from the original series—which got him hired within hours.

Robert Beltran auditioned for Chakotay without knowing anything about the Star Trek franchise or the significance of the role; he simply liked the script he received from his agent.

The series was developed in 1993 while The Next Generation's final season and Deep Space Nine's second season were still in production, with backstory elements like the Maquis planted in episodes of both shows to set up Voyager.

Voyager was shot on the same soundstages previously used for The Next Generation, and the pilot episode 'Caretaker' was filmed there in September 1994, taking 31 days to shoot and becoming one of the most expensive TV pilots made to that date.

Star Trek: Voyager was the first Star Trek series to use CGI instead of physical models for exterior space shots, transitioning to full CGI for certain shot types midway through season three, with the episode 'The Swarm' being the first to use Foundation Imaging's effects exclusively.

Unlike The Next Generation, which reused Jerry Goldsmith's theme from Star Trek: The Motion Picture, Goldsmith composed and conducted an entirely new main theme specifically for Voyager, which Newsweek later called the best theme of all Star Trek TV series.

The USS Voyager sets were reused for other productions: the ship's sickbay set doubled as the Enterprise-E sickbay in Star Trek: First Contact and Insurrection, and the ready room and engineering sets appeared as rooms aboard the Enterprise-E in Insurrection.

During the COVID-19 pandemic in May 2020, the Voyager cast held a live virtual reunion that broke the Stars in the House single-episode fundraising record, raising $19,225 for The Actors Fund, surpassing the previous record set by a Glee reunion.

A crowdfunded documentary about Voyager, 'To the Journey: Looking Back at Star Trek: Voyager,' became the most funded crowdfunded documentary ever, raising over $1.2 million from more than 11,000 donors by the end of March 2021.

In 2015, astronaut Samantha Cristoforetti tweeted Captain Janeway's line 'There's coffee in that nebula' from the International Space Station while wearing a Star Trek uniform, timed to the arrival of the ISSpresso coffee machine aboard a cargo spacecraft.