Development According to director
Anubhav Sinha, the idea of
Ra.One originated in 2005 when he saw an advertisement on television which showed children remotely controlling a human. He was attracted to the concept and wrote a script based on it. Sinha then approached
Shah Rukh Khan, who liked the story and decided to produce the film under his production company
Red Chillies Entertainment. He stated that he wanted to "make a film that gives me the right to deserve the iconic status that I've got for 20 years", and also said that he wanted to make a film dedicated to father-son relationships, which were, in his opinion, "neglected" in Bollywood. Khan's idea was to make a simple
family drama which expanded into an
action film. He declined to make the film in English to increase its appeal for Western audiences, feeling that "cracking Hollywood on their terms" was unnecessary. Both Khan and Sinha credited their children for providing encouragement and regularly "approving" the film's execution. After providing the visual effects for
My Name Is Khan (2010), the studio focused solely on
Ra.One and did not take up any other films. Khan initially approached a number of directors to helm the film, including
Aditya Chopra and
Karan Johar, but they declined; eventually, Sinha was made as the film's director. To prepare the film's premises and characterisation, Sinha spent several months viewing video clips,
digital art portals and
comic books. The
storyboards were designed by Atul Chouthmal, who was contracted after he met Khan at
Yash Raj Studios. While the former began work on the storyboards, the producers hired a storyboard artist from Hollywood. Chouthmal revealed that Khan and the other artist differed on their visions of the film, and so he was brought back. Before filming, Khan reportedly took tips from actor
Kamal Haasan regarding the production of large-scale films, having been impressed by Haasan's
Dasavathaaram (2008). The title of the film received significant media attention due to it being the name of the antagonist rather than the protagonist. The move was considered innovative and noted as a sign of the "rising importance of the villain in Bollywood." According to Sinha, the title had not been planned as such, and was ultimately chosen because
Ra.One "sounded cooler" than
G.One. Khan was advised to name the film after his own character; he declined to do so, citing the inter-dependence between good and evil. He also called
Alfred Hitchcock as his inspiration, and pointed out that the antagonists in films like
Sholay,
Mr. India and
Sadak were better remembered than the protagonists.
Arjun Rampal accepted the role of Ra.One after Anubhav Sinha expressed a strong desire to cast him in the film.
Tom Wu was contracted to the film in July 2010 and
Shahana Goswami was cast one month later.
Amitabh Bachchan agreed to be a part of the film after being requested by Khan and Sinha. Several cast members prepared extensively for their roles; Rampal and Kapoor followed special diets to lose weight, Khan and Verma performed their own stunts and Kapoor subsequently did so as well despite initial reluctance. The cast encountered problems during production, Khan
faced difficulties with his superhero suit and
prosthetic makeup and injured his left knee. The decision to cast Rampal was met with scepticism due to "questionable acting abilities", a statement Sinha criticised.
Jackie Chan had initially been approached for the role of Aakaashi, but he declined the offer.
Rajinikanth suffered from health problems which caused a delay in the filming of his cameo appearance.
Sanjay Dutt faced a scheduling conflict with
Agneepath (2012), which was later resolved.
Filming The crew of
Ra.One featured both Indian and overseas personnel.
Nicola Pecorini served as the director of photography with
V. Manikandan providing assistance. The film's producer was Bobby Chawla, but
Gauri Khan later stepped in after the former suffered a
brain haemorrhage. Filming took place at a number of studios, notably
Filmistan Studios,
Film City and
Yash Raj Studios in India and the Black Hangar Studios in the
UK.
Principal photography was initially set to begin in
Miami, but the idea was abandoned due to budget constraints. The first phase of filming began in
Goa on 21 March 2010 and continued until May. The second and third phases took place in London with the entire cast, beginning in July 2010 and ending in August. The next phase was split into two schedules; the first schedule commenced at Filmistan Studios in the first week of September 2010, while the second schedule began in December 2010 and took place over a seven-day period. The remaining portions were filmed in July 2011 at Film City. A cameo appearance and a music video were filmed in the weeks leading up to the release, the former at the Whistling Woods Studios in Mumbai.
Ra.One featured three major action sequences, which were filmed in sets and real locations across Mumbai and London. The cinematography borrowed ideas from
video games, such as rapid transitions between first-person and third-person perspectives. The production design was closely associated with the lighting and cinematography to facilitate smooth filming. Prime Focus carried out the film's 3-D conversion with London-based colorist Richard Fearon performing the
colour grading. Red Chillies VFX partnered with a number of visual effects studios around the world and undertook the incorporation of the visual effects under the supervision of Jeffrey Kleiser.
Nvidia provided the information technology–based software utilised for the effects, while Edwark Quirk supervised over the
computer-generated imagery used in the film. and the required sound enhancements were achieved by using the
Dolby Surround 7.1 system. and was preceded by extensive research. A number of complex procedures were executed, including cubical transformations and the design of the faceless form of Ra.One. increased work-load due to the 3-D and dubbed versions of the film, and delays in the completion of the visual effects. The post-production also faced budget constraints
Costumes The bodysuits worn by Khan and Rampal were designed by
Robert Kurtzman and Tim Flattery, and made by a team of specialists based in
Los Angeles. Sinha spent around three months conceptualising the costumes, watching various superhero films to design a costume, which is not created already. He then wrote a 23-page document with his sketches and details of what he wanted and gave it to the designers to work upon. A total of 21 costumes were made for the film, with each suit reportedly costing . Khan's suit was made of reinforced
latex, coloured steel-blue and fitted with micro-computer circuitry. Rampal's suit was made of three-inch thick solid rubber, and was red in colour. Both actors were required to wear additional suits inside their body suits to prevent skin contact. Wearing the suits created a number of difficulties for the actors. It took 20 minutes to put on the suits and 40 minutes to remove them. Khan later felt that the suits' conception had been a mistake since filming occurred during the day; digital adjustments to the suits brought "all the efforts to naught". Kapoor wore a red
sari draped in the style of a
dhoti. Since the release of the song, the costume was termed a "fashion rage", becoming popular in India and some overseas countries. Fashion experts applauded the costume and Kapoor's ability to carry it off "stunningly", though certain experts dismissed the naming of the
sari colour. ==Music==