It was filmed mainly in Chicago as well as several other locations in the USA, UK and Hong Kong.
Filmed with Imax camera
Less CGI was used to disguise Chicago so many recognizable landmarks can be seen
The film is dedicated to Heath Ledger and technician Conway Wickliffe who was killed when his car crashed during the planning of a stunt
When making the face for 2 face three 720-pixel HD cameras were set up at different angles on set to fully capture Aaron Eckhart's performance. Eckhart wore markers on his face and a prosthetic skullcap, which acted as a lighting reference.
Batman Begins composers Hans Zimmer and James Newton Howard returned to score the sequel. Composition began before shooting, and during filming Nolan received an iPod with ten hours of recordings. Their nine-minute suite for the Joker, "Why So Serious?," is based around two notes. Zimmer compared its style to that of Kraftwerk, a band from his native Germany, as well as bands like The Damned. When Ledger died, Zimmer felt like scrapping and composing a new theme, but decided that he could not be sentimental and compromise the "evil [Ledger's performance] projects." Howard composed Dent's "elegant and beautiful" themes, which are brass-focused
This film introduces the bat pod which is a recreation of the batcycle. Production designer Nathan Crowley, who designed the Tumbler for Batman Begins, designed six models (built by special effects supervisor Chris Corbould) to use in the film's production, because of necessary crash scenes and possible accidents. Crowley built a prototype in Nolan's garage, before safety tests were conducted.
The bat pod is steered by the shoulder instead of the hands (extremely unorthodox) and the riders arms are protected by sleeve like “shields”. The tires are 20 inch, and are made to appear as if they have guns, rockets and a grappling hook
The bat suit is also improved, it has a wide elastic banding to help bind the costume