Trivia: We see in the movie that General Grievous is permanently coughing when he talks. The cause of this can be found in the last episode of the animated, Emmy-winning TV series "Clone Wars." In that episode, Grievous kidnaps Palpatine and before leaving into space, he is attacked by Mace Windu, who destroys part of his armor in the chest, making him cough for the first time.
Trivia: George Lucas makes a cameo appearance during the opera scene. He is the blue faced being, named Baron Papanoida, that you see outside Palpatine's box. It marks Lucas' first and only appearance in any of the Star Wars films; also in that scene is Lucas' daughter Amanda and her boyfriend. Lucas also reportedly provides the sound of General Grievous' coughing.
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Trivia: Hayden Christensen wanted to wear the Darth Vader suit in the films, as it had always been a dream of his (revealed in the DVD commentary). Though the filmmakers hesitated, as Christensen was too short, they eventually let him wear the suit onscreen, but Christensen had to look through the mouth-piece of the Darth Vader costume, not the eyes.
Trivia: George Lucas purposely made the Darth Vader suit uncomfortable, heavy, and cumbersome. This way, as Hayden Christensen walks around in the armor (especially after first being put into it), his movements seem awkward - after all, Darth Vader isn't used to wearing it yet.
Trivia: The blue-skinned Twi'lek Jedi Aayla Secura, who can be seen in this film and "Attack of the Clones", was not created by George Lucas. She originated in the Star Wars comic books from Dark Horse. After seeing a cover painting, George Lucas became so impressed that he decided to use her in the movies.