Max von Sydow's costume for the Emperor Ming weighed over 70 pounds and he could only stand in it for a few minutes at a time. See more...
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Continuity: There are a couple of instances in the movie where the models do not correspond with the actual sets. When Klytus arrives at the Hawkmen city he lands near the top of the city. Yet in that very hall there is a pit with a deep void underneath. Such a room could only exist at the bottom of the city. Also, when the Hawkmen start to land on Ajax, its engine section appears to be missing.
Other: The scenes with Flash and Aura in the shuttle are a complete mess. She tells him that the left lever controls direction, the right controls the altitude. When they are passing the planet Aquarius, she tells him to take a left turn over Fridgia. a) They are passing Aquarius at the time, not Fridgia. b) He moves the right lever instead of the left lever. c) The craft doesn't change direction or altitude and even if it had moved left as supposed to, they would have ended up crashing into Aquarius. The scene when Flash wants to talk to Dale is even worse. He pulls down the left lever to dive into Fridgia. It is the wrong lever. Then when he pulls back up, he correctly uses his right hand, but the right lever is already in the up position as seen in the previous shot.
Revealing: While Flash and Barin are fighting with the whips, Flash takes a swipe at Barin with the whip and hits him in the face. Before the whip strikes Barin, you can see the red blood on his face, we then hear the crack of the whip, Barin yanks his head back as if he had been hit and then comes back into frame smearing the red blood.
Continuity: When Dale escapes and fights the guards, the editing is really awful: first she knocks a guard, who later on changes positions. Then she walks away, leaves her shoes on the floor, and hides against a wall, but after a brusque cut she appears somewhere else, the shoes are 15 meters away and the guard from before lies in front. (I guess that some of the fighting in between was deleted.)