Development In late 2009, director
A. R. Murugadoss intended to collaborate with
Salman Khan to remake the Telugu film
Kick (2009), which was produced by
Sajid Nadiadwala. But the plans did not materialise and Murugadoss later decided to collaborate with
Suriya for another project. It was produced by
Udhayanidhi Stalin under
Red Giant Movies, in their fourth production venture following
Kuruvi (2008),
Aadhavan (2009) and
Manmadan Ambu (2010). The company made a public announcement in May 2010, also announcing the title as
7 Aum Arivu. The technical crew includes music composer
Harris Jayaraj, cinematographer
Ravi K. Chandran, editor
Anthony and production designer
Rajeevan. Though people worship him for spreading
Zen Buddhism and martial arts, and being deified in several parts of the world, there had been minimal awareness in India. As a result, he researched extensively on providing details that referred to Bodhidharma and his ancestors. It took him nearly ten-months for the pre-production. Murugadoss further admitted that the film's first 15 minutes would be set during the 6th century on tracking Bodhidharma's origins and remain completely authentic, while the outstanding portions were to be set in the present period.
Casting Suriya portrayed two different roles—one being Bodhidharma, and the other being his fictional descendant, a circus artist. Speaking to Radhika Rajamani of
Rediff.com, he said it took him a long time to authentically portray the character, and a lot of effort was required. The film marked
Shruti Haasan's Tamil debut as a lead actress, after having previously acted in Hindi and Telugu films. She played the role of a scientist researching Bodhidharma's roots. Murugadoss said he wanted a beautiful and intelligent woman, hence he chose Haasan for the role. He received the offer when he was in contact with Peter Hein, and the latter recommended his name to Murugadoss for someone who can perform numerous action sequences. Describing his experience in the film, Trí Nguyễn stated: "There are quite a few scenes that have elaborate fights between Suriya and me [...] When I started work on
7am Arivu, I had no expectations. But I was pleasantly surprised when Murugadoss asked me to shoot a lengthy action scene on a highway in the middle of a traffic jam on the very first day of the schedule. Cars were flipping and vehicles were crashing all around. I was quite surprised when I learnt about the unit's pre-production work and the number of days they spent in choreographing the scene."
Ashwin Kakumanu was cast in a supporting role after Murugadoss saw him in
Nadunisi Naaygal (2011).
Dhanya Balakrishna had stated that though her friends were against her taking up supporting roles, it did not stop her from accepting one in
7 Aum Arivu. Malayalam actress
Urmila Unni made her Tamil debut in the film.
Filming Principal photography began in June 2010 at
Chennai. The team shot a sequence at the
Ampa Skywalk, followed by the song "Oh Ringa Ringa". It was filmed in over 40 locations in and around the city, including
Besant Nagar and
Ranganathan Street in
T. Nagar, with around 500–1000 junior artists who rehearsed their dance choreography at the AVM Studios for three days. According to the song choreographer
Shobi, "The place is so crowded that two people cant even walk side by side at a given time. But, we made Suriya, along with 500 other dancers, shake their legs to the number. We shot the sequence using hidden cameras." In late August, Haasan suffered an elbow injury during the filming of a stunt sequence. Later in early December, Suriya had a spinal injury after a stunt sequence. By August 2010, the team moved to
Coimbatore for filming the circus portions at the Great Bombay Circus, and Suriya performed the trapeze acts under the supervision of Pratap Master. On shooting in China, Suriya added that the people there were excited and had learnt new things, while also adding that "At 3 am, the whole crew (
even kids) would be ready with their costumes and make-up. It was not a burden for them; it was not like working on another project, it was like worship for them, it was like being in a temple. The discipline and respect they showed and the support they gave was amazing." Shabina Khan designed the costumes for Suriya and Haasan, staying with the team throughout the filming process. Afterwards, the team moved to Chennai for filming the climax sequence in the
Tambaram and
Pallavaram bypass area. Despite shooting 80 percent of the film, Ravi K. Chandran left the project as his dates clashed with
Agneepath (2012), but returned in May 2011. Filming continued for over a year before
wrapping in July 2011.
Post-production Suriya began dubbing for his portions in the film and completed it by July 2011.
Legacy Effects handled the
visual effects supervision in their second Indian film after
Enthiran (2010). The budget of the film was estimated to be around to . == Themes and influences ==