Bale spends much of the film in the Batsuit, a tight-fitting rubber costume which comes with a mask and cowl, and said that he found it difficult to breathe in the suit while filming the franchise's third instalment.
"When it gets cold the cowl is extremely tight, and it gets better the warmer I get it; it becomes more flexible," Bale told Empire
"But after a couple of takes I was trying to breathe properly in my nose. I was starting to see stars and I said, 'I have to take this off'.
"And thank God, on this one I can - on Batman Begins I couldn't - so I had to get inside because I couldn't let anybody see me without the cowl."
Bale's co-star Anne Hathaway revealed that she came to regard her Catwoman costume as "a psychological terrorist", because of the constant pressure she was under to fit into it.
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The Dark Knight Rises opens on July 20. Watch a trailer below: