Development On 25 October 2022,
John & Mary Creative, the newly launched production house of former minister
Shibu Baby John, announced their debut film which brought together director
Lijo Jose Pellissery and actor
Mohanlal for the first time. The title was announced on 22 December. At that time, media reported that the film is a period drama in which Mohanlal portrays the role of a wrestler. The screenplay was written by
P. S. Rafeeque. Pellissery retained most of the technical crew from his previous films.
Tinu Pappachan was appointed as the associate director. The film credits Shibu Baby John and Achu Baby John from John & Mary Creative, Kochumon Century from
Century Films, Jacob K. Babu from
Maxlab Cinemas and Entertainments, and Vikram Mehra and Siddharth Anand Kumar from
Yoodlee Films as producers. According to John,
Malaikottai Vaaliban is a "complete action cinema". Mohanlal stated that the film is crafted in the style of a
Western film, and the storyline is not confined to any specific time period. The narrative unfolds in
its own world, transcending space and time, blending philosophical and spiritual elements. The film allows for individual interpretations, with Mohanlal stating, "each viewer's perspective would be as diverse and unique as strokes of a painting". Additionally, he suggested that it could also be perceived as a cinematic
zen story. Pelissery added that the film is without any particular genre and can be perceived as a cinematic rendition of an
Amar Chitra Katha. According to producer Siddharth Anand Kumar, "it is the kind of epic story we have grown up reading", it may look like a mythological story, "but it is outside of the mythological space".
Casting Commenting on Mohanlal's casting, Pellisserry emphasized that, "this is a period film which demanded someone with the gravitas of Mohanlal". Describing the character, Mohanlal said that there is an anonymity surrounding Vaaliban, as he can be anyone and possess any ability. In November 2022, the team entered into discussions with actress
Radhika Apte for the lead female role, according to reports. There were also reports of
Vidyut Jammwal and
Rajpal Yadav being considered for roles in the film. In December,
Kannada actor and stand-up comedian
Danish Sait confirmed that he would make his Malayalam cinema debut in the film, growing a beard for his role, which contrasts with his typical clean-shaven appearance. Sait's character was designed to emulate the traits of a
hyena, a concept developed during discussions between Mohanlal and Pellisery. Sait underwent specific preparations for his role. He was asked to watch hyena videos to capture the character's behaviour and laughter. In the film, he spots a half-shaven head and beard look. Sait himself dubbed his voice in Malayalam,
Hindi,
Kannada, and
Tamil language versions of the film. He was first considered for another Pellissery film, which was postponed, prior to his casting in
Malaikottai Vaaliban.
Marathi actress
Sonalee Kulkarni also made her Malayalam debut with the film, describing it as a "musical period drama". She plays Rangapattinam Rangarani, an actress and dancer. Pellissery discovered Kulkarni from a Marathi film,
Natarang (2010), where she played a
lavani dancer, which she performs in
Malaikottai Vaaliban as well. Describing her character, Kulkarni said that Rangarani has "a touch of
Maharashtra" but comes from somewhere else; her outfit and looks are a fusion of many Indian cultures, "there is far too much diversity in this film because every character, not just Rangarani, is from distinct lands". In January 2023, reports suggested that the team was in talks with
Tamil actors
Kamal Haasan and
Jiiva for two brief roles. It was later reported that Haasan declined the role as he wanted to focus on his work in
Indian 2. Kannada actor
Rishab Shetty dismissed reports about his casting, clarifying that although he was approached for a role, he turned down the role in favor of a
Kannada film. In the turn of events, Mohanlal himself was cast in a
second role that unfolds during the film's climax, originally considered for either Haasan or Shetty.
Malayali dancer Manoj Moses secured an important role, as did
Bengali actress Katha Nandi, who described her part as a "strong female character". Moses was cast because Pellissery wanted someone who knows
acrobatics, having noticed him in his unreleased debut film,
Moonwalk. Hariprashanth Varma's character look came out as location pictures in February 2023. Sanjana Chandran, a dancer and trans woman, secured a role in the cast and made her acting debut. Television actress Suchitra Nair was cast by Pellissery after he spotted her on the Malayalam reality TV show
Bigg Boss (season 4), marking her film debut.
Hareesh Peradi,
Manikandan R. Achari, and
Rajeev Pillai was also cast in undisclosed roles.
Bharatanatyam dancer
Shanta Dhananjayan plays a
kalaripayattu gurukkal in the film. Deepali Vashistha, a
belly dancer was also cast in the film. Russian yoga teacher, dancer, and model Diana Nasonova played another role.
Filming was a major location.
Principal photography for the film began with a customary
pooja function on 18 January 2023 in
Jaisalmer,
Rajasthan.
Madhu Neelakandan was the cinematographer. The majority of the film was shot in
Rajasthan. The production was relocated to
Pokhran, Rajasthan on 24 February for further shooting. After a span of 77 days, the schedule in Rajasthan was completed by the first week of April. The second schedule was planned at Sree Gokulam Film Studios in
Chennai. The schedule began in early May, utilising sets built for the film. The film used more than 1500
extras on set. The film in its entirety was completed in approximately 130 days shooting. Stunts were choreographed by Vikram Mor and Supreme Sundar. == Music ==