Bill Paxton had tried to get a sequel to Twister off the ground for years. After seeing success as the director of films like Frailty (2001), Paxton wanted to direct a modernized telling of the 1925 Tri-State tornado that took the lives of 751 people, and would focus on one single tornado that travels through several states. Paxton, with the help of producer James Cameron, also wanted the film to have an MPAA R-rating and maintain a realistic depiction of the damages that real tornadoes cause, and planned for it to be shot in 3D. The film at one point had an unofficial schedule date for the summer of 2012 under the name "Twister 3D", but it was ultimately canceled due to budgetary concerns and, years later, by Paxton's death in 2017.
Interior sets were shot at Prairie Surf Studios in downtown Oklahoma City, which was also housing Killers of the Flower Moon (2023) and Tulsa King (2022) at the same time.
Production was originally to take place in and around Los Angeles, California before it was decided by director Lee Isaac Chung, who had grown up in the midwestern United States, that the film should be shot on location in Oklahoma. The first Twister from 1996 also went through a similar process, where Jan de Bont demanded that the film also be shot in Oklahoma and threatened to leave production if it wasn't.
Helen Hunt, who starred in the 1996 film, pitched her version of a Twister sequel to Universal in July 2020, with a story involving the science team at an Oklahoma historically black college who use their inventions to stop tornadoes. Hunt, who wanted to direct it herself and star alongside Daveed Diggs, said her idea briefly entered a developmental stage but was dismissed and canceled by the end of 2020.
The trailer shows that the tornado reading devices of the Dorothy line continue with at least Dorothy V. If there are more or not, is unknown.