The upcoming Tamil period film will be shot with motion capture in 3D, and is described as India's first performance capture photorealistic project.
Rajinikanth is cast as the archetypal superhero in an epic dramatisation of good versus evil. Hindi stars Deepika Padukone and Jackie Shroff also star in the production.
Vidya Balan and Katrina Kaif were earlier considered for the role of the female lead.
The Soundarya-directed production features a score from Grammy award-winning composer AR Rahman.
South Indian star Rajinikanth is currently shooting the latest schedule of the project in the UK, his first role since suffering health problems last year.
The film - which is expected to release in Tamil, Hindi, Telugu, English and Japanese language versions - will reportedly hit the box office Diwali 2012.