Has 92 instances of product placement of a single product: the Nokia 3310 cell phone.
To save money, the movie was shot back-to-back with Hellraiser: Deader (2005) in Romania as part of a two-film contract deal, from October through December of 2002 (though both were not released until 2005). Halfway during production of Deader, there was still no script for the second film, until one of the producers came across a story treatment by author and Dimension Films producer Joel Soisson called 'Dark Can't Breathe', based on his short story of the same name. Director Rick Bota then asked writer Carl V. Dupré to adapt this treatment into a Hellraiser film (Dupré had previously collaborated with Deader screenwriter Tim Day to re-write Bota's Hellraiser: Hellseeker (2002)). Originally called 'Hellraiser: Deadworld', the new script's many metaphysical moments and teenage characters were clearly inspired by Scream (1996), whose self-referential approach had been very successful 6 years before.
This is the last film in which Doug Bradley portrays the lead Cenobite Pinhead, making him the only actor to play the character more than once. Bradley later admitted that he did the job so many times for the money, but also because of his pleasant cooperation with director Rick Bota, and because he didn't want anyone else doing it: "I was possessive about the part, to a point."
Lance Henriksen was once considered to play Frank in the original Hellraiser (1987), but he chose to do Near Dark (1987) instead. At the wrap party, a life-sized Pinhead pinata was given to him, but he had to throw it out because he is allergic to chocolate.
Years after this film was released, a fan asked Lance Henriksen about it at a convention, but Henriksen was completely confused, as he had no memory of ever doing a Hellraiser film, and recalled that Hellworld was its own original project, unrelated to a series. However, Henriksen would sometimes make up to eight movies per year during those years; his only interaction with the puzzle box and Cenobites was in one scene only, so he may simply not have remembered the details. Also, Hellworld was originally based on a screenplay not connected to the franchise, and is only loosely connected to the series' mythology.