The series is the fourth show in The Big Bang Theory franchise and the second direct spin-off of the original sitcom, created by Chuck Lorre, Zak Penn, and Bill Prady.

An untitled Big Bang Theory spin-off was first revealed as in early development at Max on April 12, 2023, before being formally announced at the 2023 Warner Bros. Discovery upfront presentation by HBO and Max CEO Casey Bloys, who withheld plot and character details at the time.

It was reported early on that the spin-off would feature a new cast, with former Big Bang Theory actors appearing only in guest roles.

In October 2024, it was revealed the spin-off would center on Stuart Bloom, the comic book store owner who was a recurring supporting character in The Big Bang Theory, with the title Stuart Fails to Save the Universe announced in March 2025.

Chuck Lorre described the show in February 2026 as a 'science fiction action-adventure comedy,' explaining he wanted a project that pushed him out of his comfort zone with special effects and CGI, contrasting with most of his career making shows where 'two people sit on a couch and talk.'

Kevin Sussman, Brian Posehn, and Lauren Lapkus were confirmed in October 2024 to reprise their Big Bang Theory roles as Stuart Bloom, Bert Kibbler, and Denise, and all signed talent holding deals with Warner Bros. Television for the spin-off.

John Ross Bowie was announced in February 2025 to reprise his role as Barry Kripke, also signing a talent holding deal with Warner Bros. Television.

Kevin Sussman and John Ross Bowie will each play alternate-reality versions of their characters, appearing as both Stuart Bloom/Alternate Stuart Bloom and Barry Kripke/Supreme Ruler Barry Kripke.

Several actors from The Big Bang Theory such as Christine Baranski, Riki Lindhome, Teller, Joshua Malina, and Wil Wheaton appear in the spin-off, though for some it is unclear whether they are reprising their original roles or playing new characters; Jon Cryer also joins the cast.

Director and actor Jonathan Frakes is involved in the production, and Robert Duncan McNeill directs episodes of the series.

Filming for the series took place from September 2025 to February 2026.