Mercedez Roze, who portrays "Young Samus", is a contortionist and a high-level competition gymnast, and can actually roll herself up into a ball (like her on-screen video game counterpart.)
The iconic "Samus" costume was a one-of-a-kind imported from Brazil just for the show directly from its designer, Thais Yuki. Every component of the costume was custom-fitted for the designer, down to the length of fingers in the gloves, and it was a sheer coincidence that Amy Bloom (who portrays Samus in the show) was a very close match in body type to the designer in almost every regard.
It cost almost as much money to rent, ship, and maintain the Samus costume than it did to blow up the van at the end of the show.
Mega Man's body costume was a custom-made wetsuit ordered directly from a manufacturer. Generally, solid color blue wetsuits (the same color as ocean water) are not available.
The show was largely outlined over the course of a writer's retreat weekend in Santa Barbara, during which time the writers spent the nights drinking and playing old video games while recording their banter on video cameras, and their days drawing on the previous night's inspiration to create the show.
Matthew Lewis: [916] The number "916", representing the area code of the director's hometown of Sacramento, CA, appears frequently across the entire series.
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