The revival was approved by Thunderbirds co-creator Gerry Anderson after Richard Taylor, founder of Weta Workshop, visited him at Pinewood Studios while Anderson was working on New Captain Scarlet.

As early as around 2000, Gerry Anderson discussed a potential revival of Thunderbirds in an interview with Jem Roberts, anticipating that computer graphics would better capture realism; around that time a Thunderbirds video game adaptation for Game Boy Color was also in development.

The series combines CGI with live-action model effects: all scale model miniature effects and CGI were produced at Weta Workshop in New Zealand, while UK-based Milk VFX handled the final composition.

Physical sets were built using methods similar to the original 1960s series, including the use of household objects as components, before CGI characters and crafts were superimposed onto the footage of these live-action miniature sets.

Each set was individually scanned as a 3D print so that CGI elements could be accurately registered and matched to the physical environments, with details like textures, atmospheric particles and flying debris added afterward.

David Graham, who voiced Parker in the original 1960s Thunderbirds series, reprises the role of Parker in Thunderbirds Are Go.

Archive audio of Peter Dyneley, the original voice actor of Jeff Tracy, announcing the 5-1 countdown from the classic title sequence is reused in the reboot's titles and during the Thunderbirds' launch sequences.

The score, composed by brothers Ben and Nick Foster, keeps the opening theme and certain musical cues faithful to Barry Gray's original score, reworked in a contemporary orchestral style.

To promote the second series launch in the UK, a fleet of five London taxis themed after Thunderbirds vehicles (including Thunderbirds 1-4 and FAB 1) could be booked for a flat £1 fare for two days, with proceeds donated to The Children's Trust, a charity for children with brain injury.