Almost everyone in the cast became life-long friends. At LeVar Burton's 1992 wedding, Brent Spiner served as best man, and Sir Patrick Stewart, Jonathan Frakes, and Michael Dorn all served as ushers. Man of the People (1992)(#6.3) aired on that day.
When the cast decided to lobby for a salary increase, Wil Wheaton's first offer from the producers was to instead have his character promoted to Lieutenant. His response was, "So what should I tell my landlord when I can't pay my rent? 'Don't worry, I just made Lieutenant'?!"
Worf's prosthetic forehead had to be changed in season two, because the original was stolen.
Michael Dorn has said that being cast as Worf enabled him to finally break away from the "nice guy" roles he had primarily played prior to the series. Dorn's voice also got naturally deeper as a result of the vocal inflections he used for the part of Worf.
After the second season, producers planned to establish that Geordi had undergone an experimental medical procedure to permanently restore his natural eyesight and eliminate use of his VISOR. However, recognizing that the character had become a positive role model for the disabled community, producers dropped the plan.