- The film’s principal photography commenced on 1 February 2017, in Chennai and was completed that September, within 130 working days. Filming took place in Gdańsk, Poland, and Jaisalmer, Rajasthan.
- The first look posters released on 21 June 2017 became the highest retweeted first look in Twitter, close to 50,000 people.
- The teaser trailer of the film was unveiled on 21 September 2017 (coinciding Atlee’s birthday) and became the most-viewed Indian movie teaser with 34.6 million views, surpassing Kabali (2016) and Vivegam (2017), and became the first Indian movie teaser to get 1 million likes.
- Mersal completed a 100-day theatrical run on 25 January 2018.
- Vijay acts in 3 different characters for the first time in this film. Vijay’s character name in dubbed versions: Vijay Bhargav, Vijay, Dr. Bhargav (Telugu); Devanand, Dev, Dr. Anand (Hindi); Shiva Shankar, Shiva, Dr. Shankar (Kannada).
- Actress Jyothika opted for the role of Aiswarya but due to unavoidable situations, she wasn’t able to take part in the film. Instead, Actress Nithya Menon was added to the cast.
- Actor Vijay performed a few magic tricks in the film to make it more realistic. He learned magic from professional magicians from Bulgaria, the USA, and Germany.
- The film was released on 6 December 2018 in China by HGC Entertainment.
- Due to demand, the film was screened at the largest cinema theatre in Europe Grand Rex, France.
- The film was screened at the Hainan International Film Festival in Hainan, China and at the Bucheon International Fantastic Film Festival in South Korea.
- The film was a commercial success, grossing ₹260 crore (US$33 million) worldwide, becoming one of the highest-grossing Tamil films.
- Initially, reports were surfaced that Atlee will be directing Mahesh Babu after Theri, and was developing the script for the past seven months which did not happen.
- Mersal movie is a Nithya Menen in her first association with Vijay.
- The television broadcast rights were sold to Zee Tamil for ₹30 crore in July 2017. The satellite rights of the Telugu and the Malayalam dubbed versions were acquired by Star Maa and Asianet respectively. It is available on digital streaming platforms through Netflix and ZEE5 (in Tamil), Sun NXT (in Kannada), and Hotstar (in Malayalam).
- The film’s Hindi dubbed version was directly premiered on Dhinchaak TV channel (now renamed to Goldmines) on 13 March 2022.
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