It always amazes me how much sci-fi series costs like Trek. Here are my ways to cut costs.
1) minimilism like TOS
I liked the surreal set for Spectrum of the Gun, but how many time can you pull that off? There no real way around throwing money at the bridge set, however, if the ship is more "military" a somewhat stark interior could work.
2) Use unknown actors for the leads.
Stargate made do with one B level actor (Dean) and a load of no-bodys. Eureka and Warehouse 13 pretty much the same. Non sci-fi shows do this all the some, you get the best you can with the money you have.
3) CGI SFX and green screen
Sanctuary has had a fairly good time with this, although the first couple of seasons it was very obvious.
4) Eliminate the prosthetic appliance budget
Having the aliens be "almost" completely Human is a good money saver, have them be aliens through their acting. Prosthetics like the Vulcans and the Bajorians yes, Cardassians and people like Neelix no (I for one liked Neelix).
5) Smaller ship and sets with a smaller crew (extras).
Smaller set and casts yes, although if too tight it would interfere with shooting, hard to see how a "smaller" ship would save money, whether 400 feet, or a thousand, the CGI model is the same.
8) Use a Canadian forest like Stargate - There must be other locales up there.
My understanding is that location shooting is more expensive, not less. However if they can redress a modern existing set to be "future" great.
10) A self contained concept and premise that focuses more on drama and conflict.
Yes.
