Development
A reunion was first conceived in 2021 by David Yost, who had scripts for a multi-part project called Power Rangers: Quantum Continuum. He pitched the idea to multiple networks, but later revealed that the project itself was still in its early stages.[5] Yost was not credited as a writer of the special. However, Jackie Marchand, a former writer and story editor for the show, was credited as a story consultant.
In 2022, Netflix became the home for first-run Power Rangers episodes after an existing deal with Nickelodeon, inherited from Saban Brands, was allowed to expire.[6] The special, like the second half of Power Rangers Dino Fury, therefore was set to premiere on Netflix.
The title is a reference to "Once a Ranger, Always a Ranger,” the long-standing phrase used in Power Rangers; first spoken by Jason David Frank’s character, Tommy Oliver in the 2-part season premiere episode of Power Rangers Zeo. The phrase also served as the basis for the Power Rangers Operation Overdrive two-part special episode "Once a Ranger," which marked the show's 15th anniversary.
Casting
On February 25, 2022, casting sides for a character with the placeholder name "Yen" were released, though it was originally thought to be related to Power Rangers Cosmic Fury. On September 30, 2022 during Hasbro PulseCon 2022, it was announced that both Yost and Walter Jones were in the process of filming a "special anniversary" project in New Zealand. Furthermore, it was announced that Charlie Kersh would be joining the cast of the special as well. One month later, Hasbro announced the reprisals of Steve Cardenas, Catherine Sutherland, Karan Ashley, and Johnny Yong Bosch in their original roles.
Whereas the show had been a non-union production since moving to New Zealand, Once & Always was filmed under the SAG-AFTRA agreement for independent high-budget subscription video-on-demand programming.[7]
Jason David Frank and Amy Jo Johnson were originally approached but turned down offers to appear in the special. Johnson cited a host of personal reasons while Frank said he had "done enough" for the franchise and wanted to focus on his film, Legend of the White Dragon. Frank died in November 2022, after the special had been filmed.[8][9]
Filming
The cast had "weeks" of rehearsals in Auckland, Jones said.[13] Filming occurred over the course of 12 days.[14]
The sets for Angel Grove Youth Center, Rita's palace and the Dino Megazord cockpit were recreated based on extensive research, production designer Tracey Collins said.[15]
Post-production
The audio for Once & Always was the first Power Rangers media to be mixed in Dolby Atmos. Ron Wasserman, who composed the theme song and score for the original series, and the theme for Power Rangers S.P.D., returned to score the special.[16] Post-production ended in February.
A trailer was released on March 21, 2023.[17]
After Frank's death, the special's ending was followed with a clip from the denouement of the season 2 episode The Song of Guitardo, in which Kimberly and Zack play a song for Tommy to help ease his anxiety over losing his Green Ranger powers. The song led into the episode's dedication to the memories of Trang and Frank. Jones called the song's reuse "very poignant."[18][19]
