On 15 February 2022, the project was officially announced under the working title AK 61, and pre-production works for the film began the same time.[15] Kapoor also shared a still featuring Ajith in a long beard with coolers in a monochrome format, which would be the looks for his film.[16][17] As a part of the film's shoot, a huge set resembling Mount Road in Chennai would be erected at Ramoji Film City in Hyderabad, where much of the film's shoot would take place.[18][19] Vinoth recruited cinematographer Nirav Shah and editor Vijay Velukutty, who worked on Valimai, while music composer Ghibran and art director Milan, were signed on.[19] Supreme Sundar was hired to choreograph the action sequences.[20] The official title Thunivu was announced on 21 September 2022.[21][22]

The same month, John Kokken,[28][29] and Veera signed the film,[30] along with Samuthirakani[31] and Mahanadi Shankar,[32] who collaborates with Ajith after 20 years since Dheena (2001).[32] In June 2022, Nayana Sai was cast in for the film,[33] and the following month, Telugu actor Ajay,[34] and Mamathi Chari joined the film, and shot few key sequences.[35] Shaam was approached to play a negative role, but declined due to scheduling conflicts with Varisu.[36] Chirag Jani also play an important role, which he described as his "biggest role in Tamil" after Kaappaan (2019). Jani said his character is a businessman with grey shades, "not a typical villain role" and would have "a very classy, corporate look".[37] Bigg Boss 6 contestant GP Muthu's presence in the film was confirmed on 23 December 2022.[38]


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In an interview to regional media, stunt choreographer Supreme Sundar had choreographed for a 360-degree action sequence which was shot in 32 seconds. Sundar also said that Ajith was given the chance to perform other stunts as even a small mistake would require to reshoot from the beginning, but was very cooperative and enthusiastic to perform the sequence. He revealed that the first four takes did not go well, but with few minor changes, Ajith was able to perform the stunt, with the shot being perfect in the 13th take.[65]

Post-production works began simultaneously on late-October,[66] with Warrier and Ajith dubbing for their portions by November 2022.[67][68] John Kokken also dubbed for his portions in Tamil, which was the first time he did,[69] as was Chirag Jani,[37] who was assisted by Ajith in dubbing for the film, translating it in Hindi and English, due to his fluency in the languages.[37] In late December, the final edit of the film, was sent to the Central Board of Film Certification for the censoring process.[70]

The music of the film is composed by Ghibran,[71] in his 50th film as a composer and marking his second collaboration with Ajith Kumar and Boney Kapoor after scoring Valimai (2022).[72] The first single titled "Chilla Chilla" was released on 9 December 2022,[73] and the second single "Kasethan Kadavulada" on 18 December.[74] Manju Warrier provided vocals only for the video version of the song.[75] The third single "Gangstaa" was released on 25 December.[76]

The makers of Ajith Kumar's 61st project, revealed the film's title and first look on Wednesday. The film is titled Thunivu. Boney Kapoor, who is also producing the film, shared the film's first look on Twitter. He used the hashtags Thunivu, No Guts No Glory, AK61 First Look and AK61 as his caption. The film will mark the third collaboration of the actor-producer duo after the 2019 film Nerkonda Paarvai and the 2022 film Valimai. Both the films were directed by filmmaker H Vinoth, who will also be directing Thunivu.

We had previously reported that AK 61 has been titled Thunivu and that in the first look poster, Ajith will be featured sitting on a chair with a gun in his hand. The first look of Thunivu has now dropped and Ajith is seen doing exactly that amidst splattered blood and with a whole lot of swag. 006ab0faaa

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