Development Border 2 was officially announced by
J. P. Dutta,
Bhushan Kumar and
Sunny Deol on 13 June 2024 on the 27th anniversary of the
original film. Deol was retained from the original cast, although the makers did not reveal the other cast members.
Casting Sunny Deol was offered the lead role following the success of
Gadar 2 (2023). While
J. P. Dutta proposed the sequel to Deol back in 2015, the project was put on hold due to several of Deol’s films underperforming at the box-office. Deol was also cautious about the sequel, wanting to ensure the story provided a natural evolution for the beloved original characters. He felt the script needed to justify a comeback to avoid disappointing fans who expect the same level of impact seen in
Gadar 2. Following the success of his recent films, Deol agreed to star in the project.
Ayushmann Khurrana was rumoured to have been offered the role of
Major Hoshiar Singh Dahiya. However, media reports indicated he was no longer part of the cast. There was no official confirmation as to whether he opted out or was dropped by the producers, leaving his exit a subject of speculation.
Varun Dhawan was then cast to play the role. The makers announced his casting alongside Deol, Diljit Dosanjh, and Ahan Shetty. Shortly thereafter, his role was cemented in the public eye as behind-the-scenes footage from the shoot emerged.
Diljit Dosanjh was signed to play the role of the
Indian Air Force officer,
Flying Officer Nirmal Jit Singh Sekhon. However, rumors surfaced that he had opted out of the film due to external project controversies. Despite the ambiguity that surrounded his status, it was later confirmed Dosanjh was firmly back on board and was set to star as one of the film's lead characters.
Ahan Shetty joined the cast as a new recruit, a move that was officially announced by lead actor Deol. Ahan played the role of the
Indian Navy officer,
Lieutenant Commander Mahendra Singh Rawat (character based on
Captain Mahendra Nath Mulla).
Mona Singh was cast opposite Deol. She portrays the wife of Fateh Singh Kaler.
Sonam Bajwa was cast opposite Dosanjh. She portrays Manjit Kaur Sekhon, the wife of Nirmal Jit Singh Sekhon. Several media outlets reported actress
Rashmika Mandanna was offered one of the other two female lead roles for a rumored ₹2–3 crore fee, although the casting was not confirmed. Medha Rana was cast opposite Dhawan. She portrays Dhano Devi, the wife of Hoshiar Singh Dahiya.
Anya Singh was cast opposite Ahan, portraying the role of Sudha, the wife of Mahendra Singh Rawat. In the second phase, which took place in
Maharashtra from early to June 2025, a major portion of the film was filmed at the
National Defence Academy (NDA) in
Khadakwasla near
Pune. This filming schedule focused on the protagonists' introductory sequences and training. Sunny Deol, Varun Dhawan,
Diljit Dosanjh, and
Ahan Shetty filmed scenes involving staged military drills, which included
NCC cadets as background extras. As production entered its third phase in
Uttarakhand during mid - 2025, the focus shifted to the rugged terrain of Uttarakhand, which served as the primary backdrop for the film's combat sequences. Sunny Deol participated in this leg of the shoot, which combined constructed sets with natural landscapes to depict
land and
mountain warfare. In Halduwala, a village in
Dehradun district, the production team built sets to replicate Kashmiri villages for the film's battle scenes. Additional filming occurred at Kimadi village and Santala Devi Temple. The production then expanded into
Almora district, where scenes were filmed at historic sites including
Jageshwar. The fourth phase took place in
Punjab from mid – late 2025, where filming was done in the state, primarily in
Amritsar district. Scenes were shot in local villages and on sets built to resemble
military camps. After individual character arcs were completed by mid-2025, a final production phase occurred in December 2025. This period focused on the film's climax, which featured several large-scale action sequences. Additional filming was done in
Jammu and Kashmir,
Rajasthan, and
Military Bases, following the initial schedule. In
Srinagar, scenes were filmed at the
Khanqah-e-Moula shrine. The Rajasthan portion of the shoot utilized
desert terrain for
desert warfare conditions. Production also took place at undisclosed
air and
naval bases for the sequences involving those military branches. == Soundtrack ==