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On April 5, 1994, Mann was reported to have abandoned his earlier plan to shoot a biopic of James Dean in favor of directing Heat, producing it with Art Linson. The film was marketed as the first onscreen appearance of Al Pacino and Robert De Niro together in the same scene – both actors had previously starred in The Godfather Part II, but owing to the film's double story structure, they were never seen in the same scene. Pacino and De Niro were Mann's first choices for the roles of Hanna and McCauley, respectively, and they both immediately agreed to act.
Mann assigned Janice Polley, a former collaborator on The Last of the Mohicans, as the film's location manager. Scouting locations lasted from August to December 1994. Mann requested locations that had not appeared on film before, in which Polley was successful – fewer than 10 of the 85 filming locations were previously used. The most challenging shooting location proved to be Los Angeles International Airport, with the film crew almost missing out due to a threat to the airport by the Unabomber. On the DVD commentary, Mann noted it would be impossible to film the airport climax in the same way following the events of 9/11.
To make the long shootout more realistic they hired British exSpecial Air Service sergeant Andy McNab as a technical weapons trainer and adviser. He designed a weapons training curriculum to train the actors for three months using live ammunition before shooting with blanks for the actual take and worked with training them for the bank robbery.
De Niro was the first cast member to receive the film script, showing it to Pacino, who also wanted to be a part of the film. De Niro believed Heat was a "very good story, had a particular feel to it, a reality and authenticity. In 2016, Pacino revealed that he viewed his character as having been under the influence of cocaine throughout the whole film.
In order to prepare the actors for the roles of McCauley's crew, Mann took Kilmer, Sizemore, and De Niro to Folsom State Prison to interview actual career criminals. While researching her role, Judd met several former prostitutes who became housewives.
Initially, Keanu Reeves was offered the role of Chris Shiherlis, which he turned down in favor of playing Hamlet at the Royal Manitoba Theatre Centre. As a result, Val Kilmer was given the role.
Prior to being cast as Ralph, Berkeley played Waingro in L.A. Takedown.
Principal photography for Heat lasted 107 days during the summer of 1995.
All of the shooting was done on location, due to Mann's decision not to use a soundstage.