Several actresses were considered for the lead female role including Taapsee Pannu, Samantha Ruth Prabhu, Sonakshi Sinha and Anushka Sharma, with Kajal Aggarwal eventually grabbing the role. Kannada actress Tara was signed on to play the mother to Suriya's character. Prakash Raj was dropped from the film and was replaced by Sachin Khedekar who had played notable roles in Yaavarum Nalam and Deiva Thirumagal.Daniel Balaji was said to be a part of the cast but he denied that he was a part of the crew. Hindi actor Milind Soman was also wrongly reported to be working for the film.
Maattrraan was officially launched on 22 July 2011 in Chennai. The first schedule was held near the Pakistan border. In November 2011, the crew filmed a song in Latvia A major portion of the film was shot in the Balkan region in countries like Croatia, Serbia, Albania, Macedonia and especially a large chunk in Latvia. Another large portion was filmed in sets erected at Ramoji Film City in Hyderabad. In February 2012, the team left for the United States to do special facial scanning led by VFX Supervisor V. Srinivas Mohan. Maattrraan thus became the first Indian film to use performance capture technology. Isha Sharvani performed an item number for a song titled "Theeyae Theeyae" which was shot at AVM Studios. Furthermore, a duet song featuring Kajal and Suriya was shot at Wai, a village near Pune in Maharashtra.Moreover, many CG scenes were shot at Balu Mahendra studios. A song featuring over 500 junior artists and Suriya was shot in Jodhpur, touted to be the last phase of canning songs. Next, filming for an important talkie portion was held at Bhuj in Gujarat near the safe zone along the Indo-Pakistani border that lasted for five days. K. V. Anand and cinematographer Soundararajan subsequently were in Madagascar, hunting for a forest location to shoot a song for the film. However, since Suriya could not afford filming there due to his other commitments, Anand decided to erect a similar set in India to create the same look as in Madagascar. The shooting which was to be held in the US, was cancelled in June 2012.The entire filming was wrapped up in Norway by completing the "Naani Koni" song in outdoor scenes shot at Trollstigen, Geiranger, Atlanterhavsveien, Måløy and Aurlandsfjorden.








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