Mihir Ahuja and Prajakta Koli reportedly underwent intensive rehearsals for Operation Safed Sagar to convincingly portray a young couple. Director Oni Sen focused on script readings, improvisation and workshops to build their chemistry before filming

Dia Mirza opened up about playing Kamalpreet Kaur Dhanoa in Operation Safed Sagar, saying the role helped her understand the resilience of Air Force wives and the emotional strength they show while their husbands serve the nation