The film was officially announced in October 2024 under the tentative title Suriya 45, as it is the actor's 45th film in a leading role. Principal photography commenced the following month in Pollachi. The official title was announced in June 2025. The film has music composed by Sai Abhyankkar, cinematography handled by G. K. Vishnu and editing by R. Kalaivanan.
In September 2024, it was reported that Suriya would collaborate with RJ Balaji for the former's third directorial venture.[2] Balaji had written a script which was initially narrated to Vijay for his 69th film,[3][4] but did not progress.[a] He then subsequently met Suriya, before the release of Kanguva (2024) and had narrated the same script, which the actor being impressed.[2] The film was intended to commence after Suriya had completed shooting for Retro (2025).[7][8] The project was reportedly produced by S. R. Prabhu and S. R. Prakash Babu's Dream Warrior Pictures, collaborating with the actor for the second time after NGK (2019).[9]
The company made a public announcement on 14 October 2024,[10] confirming the project, tentatively titledSuriya 45, as it was the lead actor's 45th film.[11][12] The announcement poster, which released on the same day, featured a collection of lengthy sickles and spears with a horse galloping between it, led to speculations about the film being a mythological or fantasy drama.[13] Ashwin Ravichandran, Rahul Raj, T. S. Gopi Krishnan and Karan Aravind Kumar co-wrote the script with Balaji.[14] In late November, G. K. Vishnu was confirmed as the cinematographer, returning to Tamil cinema after six years since Bigil (2019).[15][16] The following month, editor R. Kalaivanan, production designer Arun Venjaramoodu and action choreographer Vikram Mor were announced as a part of the technical crew.[17] The film's official title Karuppu was announced on 20 June 2025, Balaji's birthday.[18]
Casting
In November, it was reported that Trisha had been cast as the lead actress in her fifth collaboration with Suriya, following Mounam Pesiyadhe (2002), Ayutha Ezhuthu (2004), Aaru (2005), and Manmadan Ambu (2010);[19][b] her participation was confirmed only on 14 December.[20] The following day, the producers confirmed the casting of Indrans and Swasika, although the latter had earlier hinted at her involvement via social media.[21][22] Subsequently, Yogi Babu,[23]Sshivada,[24]Natty Subramaniam,[25]Supreeth Reddy and Anagha Maaya Ravi were announced as a part of the cast the same month.[26] The film would further mark the Tamil debut of Anagha.[26]
Filming
Principal photography began with an inaugural puja ceremony on 27 November 2024 at Masani Amman temple in Pollachi with the presence of the film's cast and crew.[27] The first schedule commenced the following day in Coimbatore.[28][29] In early December, pictures from the sets leaked online which featured Trisha and Suriya dressed as lawyers, leading to speculation about their characters.[30] By mid-February 2025, the team planned to shoot key sequences at the East Coast Road (ECR) in Chennai.[31] During filming at Velichal in the Kelambakkam–Vandalur stretch, the makeshift platforms set by the art direction team, resulted in unexpected roadblocks which led to the concerned local villagers informing to the authorities. In response, the police intervened and halted filming, citing that the makers failed to obtain proper permissions for shooting and the officials advised the production team to secure prior approval from the Tambaram Metropolitan Police Commissioner's office. This resulted in the planned schedule to be cancelled.[32]
In early March 2025, the team moved to Hyderabad for filming a crucial sequence at the Ramoji Film City.[33] Later that month, the production team planned for a song shoot resembling a festive backdrop.[34] Arun Venjaramoodu constructed a huge set at the Adityaram Studios in ECR for a song sequence that featured over 500 dancers beside the lead actors, and the song would be choreographed by Shobi.[35][36] In early May, it was reported that filming was planned to wrap later that month.[37]
Music
The soundtrack was initially announced to be composed by A. R. Rahman in what would have been his fourth with Suriya in the lead, after Aayutha Ezhuthu (2004), Sillunu Oru Kaadhal (2006), and 24 (2016).[38] However, Rahman opted out for unknown reasons, and on 9 December, Sai Abhyankkar was announced as the new composer.[39]
The first teaser was released on 23 July 2025, Suriya's birthday. It revealed his character's name to be Saravanan, a reference to the actor's real name, confirmed speculation that he would be playing a lawyer, and includes references to his previous films such as Ghajini (2005).[40]
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