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The film was the result of a complex development process, starting with the director's idea of directing and co-producing Sultan: The Warrior with Eros International in 2007, which was to feature Rajinikanth as a computer animated character.[7] After cancelling the project due to lack of financial support,[8] Soundarya and Eros turned their attention to producing Rana, which was to be a live-action historical fiction film directed by Ravikumar starring Rajinikanth and Padukone. However, the project was put on hold after Rajinikanth fell ill and uncertainty remained whether Rana would resume. In the meantime, producer Dr. J. Murali Manohar felt impressed by Soundarya's draft work on Sultan and persuaded her to materialise her directorial ambitions with Kochadaiiyaan, featuring a plot which leads itself up to the events of Rana, which was later deciphered as a sequel script to Kochadaiiyaan.[9] The team agreed and completed filming in two years with Centroid Motion Capture at Pinewood Studios in the United Kingdom using motion capture technology, after which animation work and post-production ensued in the United States, Hong Kong, and China for a year.[3][10][11][12] Music for the film was composed by A. R. Rahman and was performed by the London Session Orchestra.[13] Rahman had been working with Kevin Lima for the later shelved film Bollywood Superstar Monkey and was inspired to bring motion capture technology to Indian cinema, hence he was also at the forefront in the film's development.[14]
Kochadaiiyaan was promoted as "a tribute to the centennial of Indian cinema" and released worldwide in 3D and for traditional viewing on 23 May 2014 in Tamil and five additional languages, including Hindi, Telugu, Bengali, Marathi and Punjabi.[15][16] Overall, the film received a mixed critical response worldwide, wherein critics drew comparisons to other films that have used motion capture technology, notably Avatar (2009), and noted general discrepancies in the animation. Other aspects of the film, including performances, background score, and screenplay, received acclaim.[17] The film had a large opening in Tamil Nadu and across the world, while a less enthusiastic reception was seen in other parts of India. Though the film fared well[18] in Tamil, it performed poorly in other parts of India, including Andhra Pradesh and Karnataka.[19][20][21] The film eventually bombed at the box office leaving distributors in huge losses and producers in financial tangle.[22][23]
After the release of Enthiran (2010), Rajinikanth approached K. S. Ravikumar to help complete an animation feature that Soundarya Rajinikanth had begun in 2007. The project titled Sultan: The Warrior had run into problems with its production and Rajinikanth hoped that they could salvage the project by adding a historical back plot which would make the film partially animation and partially live action. Ravikumar then developed a story for fifteen days with his team of assistants and after being impressed by the script, Rajinikanth felt that Ravikumar's story should be an entirely separate film. Thus the team launched a venture titled Rana, to be jointly produced by Ocher Picture Productions and Eros International. The film would have featured cinematographer R. Rathnavelu and music would have been composed by A. R. Rahman.[27][28] Principal photography, began on 29 April 2011. However, during the first schedule of filming, Rajinikanth fell ill on sets and was admitted to hospital where he was treated for dehydration and exhaustion for over a month, resulting in an indefinite postponement of filming. Further attempts for the film to continue production throughout the year failed.[29][30] On 23 November 2011, for her maiden directorial project, Soundarya tweeted through her Twitter account, notifying followers to watch out for an official announcement.[31] Following the delay, the team considered making Rana as an animation film but Rajinikanth was insistent that the film would be a live action film. Film producer Murali Manohar then suggested that an animation film could potentially be a sequel to Rana and thus the team began work on Kochadaiiyaan. A tentatively scheduled release period of August 2012 was also announced.[32]
The film was finalised to be a co-production of Eros Entertainment and Media One Global.[33] Soundarya further stated that Ravikumar had worked with her father and herself on the script of the film.[34] With regards to the film's title, Ravikumar claimed that it drew reference to an alternate name of Hindu deity Shiva, while also being partly inspired by the name of the Pandya Dynasty king Kochadaiyan Ranadhiran, and that the plot would be a fictional account with small references to Indian history.[35] The title's etymology was defined by Vairamuthu who deconstructed it into its root words, which collectively meant "king with a long, curly mane."[5] The director clarified that Kochadaiiyaan was not related to the same-titled history series being published by the Tamil magazine Kumudam.[36] When rumours circulated that the temporarily shelved feature Rana was being remade as Kochadaiiyaan, Ravikumar denied these rumours saying, "Kochadaiyaan has nothing to do with Ranadheeran or Rana." Latha Rajinikanth also clarified that the film would serve as a prequel to Rana.[37] In October 2013, the name of the film was changed from Kochadaiyaan to Kochadaiiyaan on Rajinikanth's request citing numerological reasons.[38]
The film began to increase its casting profile after Malayalam actor Prithviraj was rumoured to have been signed to play an important role in the film.[52] The rumour was falsified following the inclusion of Aadhi, who was known for his lead-role performances in Mirugam and Eeram, in the cast; when he confirmed his presence in the project, he remarked that working with Rajinikanth was "a realisation of a dream that he has had since childhood".[53] Sneha was reported to be finalised for a supporting role,[54] with the actress confirming her presence in the film in December 2011.[55] She, however, opted-out a couple of months later citing conflicts in her schedule and Rukmini Vijayakumar was signed in her place.[56] R. Sarathkumar accepted Soundarya's offer for an important role in the film while veteran actor Nassar was recruited in the film as well for a supporting role.[41][57]
Furthermore, Shobana and Lakshmi Manchu were said to be considered for a role in the film.[58] Soundarya confirmed that the former was added to the cast saying that she was the "only choice for the role" as the character was written keeping her in mind.[59][60] Soundarya disclaimed the rumour that Aishwarya Rai was chosen to do a guest appearance in the film.[61] Bollywood actor Jackie Shroff was also approached for an antagonistic role.[62] Shroff immediately gave his consent, when the cast and the technical scope of Kochadaiiyaan were revealed to him.[63] Reports claimed that the film would feature late actors like Nagesh, P. S. Veerappa, M. N. Nambiar, S. A. Ashokan, and R. S. Manohar recreated through sophisticated animation techniques,[64] although it was later revealed that only Nagesh was recreated for the film. According to Soundarya, "The biggest triumph for Kochadaiiyaan was bringing back late comedy actor Nagesh to the screen."[3]
Peter Hein was chosen as the film's action choreographer,[65] while A. R. Rahman agreed to compose the film's background score and soundtrack.[66][67] Soundarya chose Saroj Khan, Raju Sundaram, Chinni Prakash and his wife Surekha Chinni Prakash, and Sivashankar to choreograph the songs.[68] Soundarya invited art professionals to send their work as she was forming an art department for Kochadaiiyaan.[69] She chose 42 students from the Government College of Fine Arts, Chennai for the task, besides 50 experienced persons from the Jacob College of Fine Arts. 60 concept artistes were already reportedly working for the film.[70]
On Rajinikanth's looks, Soundarya quoted: "First, we scanned his face and made a 3D model to get the exact precision of his features, such as the scar on his nose. And then we corrected the 3D model by tightening his skin to make him look 25 years younger. They used that technology in the film Tron." The youthfulness of the look was compared to the looks that Rajinikanth carried in his film Muthu.[3] Soundarya also claimed that Rajinikanth's hairstyle in the film was inspired by his appearance in his earlier film, Thalapathi.[72]
Resul Pookutty is the sound designer for the film.[73] He worked over two and a half years on the sound design of the film. Three teams of sound editors were working in Los Angeles, Mumbai, and Chennai under him. The final phase of re-recording was done in Chennai at A. R. Rahman's studio during end-March 2014. In an interview with The Hindu he quoted, "For the war sequence, we got 150 people scream like how they would in a war and recorded the sound. I went to fortresses and collected samples of how sound resonates. Based on the impulse response data, we recreated the acoustics of a durbar." Pookutty started working from the scratch instead of using available sound samples. He added that when his team started working on the foley (ambient sounds) he told the film director to provide him with the exact costumes used whilst filming. However, realising that the filming was done using performance capture technology, the entire set of costumes were designed to provide requisite foley. He also paid attention to nuances extensively where he added, "For instance, the image you see on screen is a composite of several layers of images. The clothes, the movement, the swords and so on were created separately and put together. My team also had to add sound, layer by layer."[74]