The waterfalls scene in the movie is actually shot at a set of Athirapally Waterfalls over which VFX were added to make it look real and larger than life. The characterization of lead character Sivudu revolves around this humongous waterfalls.
It took almost 1 year for pre-production work which is highest for any Indian movie till date. The magnificent palaces, impregnable forts, breath-taking water falls were all created for the movie. Usually a 24-foot-high scale set is created, but for this movie the makers decided to go for 45-foot-high scaled sets.
The British Board of Film Classification passed the movie with a 15 rating (suitable only for 15 and over) for strong bloody violence. Interestingly, the Central Board of Film Certification (Indian censor board) passed the movie with a U/A certificate(with no cuts, even more surprising considering how strict the CBFC is for Telugu movies) which is the equivalent of BBFC's 12A rating.
Every time there is violence against animals in the movie, an indication "C.G.I." appears in the lower left corner of the screen. This is to indicate that all the violence against animals was simulated through computer graphics and actual animals were not hurt. This is one of those rules the Indian censor board insists, like the anti-smoking warning.
The role of Sivagami was first given to actress Sridevi who wanted 6 crores for accepting the role. The producers declined her demands and went to actress Ramya Krishnan which made a great casting choice for the part, according to the director.
The first opening shot of the movie was filmed on the sets of Athirappilly Falls in Kerala and director Rajamouli specifically wanted a newborn baby for that scene. But the film-makers were unable to cast a newborn baby for that part. On that tight schedule, one of the production executives from Kerala informed about his newborn child to the director, and instantly the baby was cast.
Lead actors Prabhas and Tamannaah Bhatia second second pairing after 2012 Telugu action film Rebel (2012). Coincidently in Rebel, the female love interest lead role with was first offered to Anushka Shetty who declined the project and was later replaced by Tamannaah. In Bahubali Anushka Shetty plays Prabhas' mother.
According to director S.S. Rajamouli, his father Vijayendra Prasad narrated the story of Sivakami. He was so captivated by the opening act and wanted to make the movie on her. The character of Bahubali came very last and the script later changed into the story of Bahubali.
Leading actor Prabhas didn't commit any other film projects for almost 3 years while filming Baahubali: The Beginning (2015). But he made a special dance appearance in the movie Action Jackson (2014) as himself, as a part of Bahubali's campaign in Bollywood. Telugu superstar Prabhas was unknown to Bollywood audience at that time, so actress Sonakshi Sinha who was featured in the song even calls his name 'Prabhas' during the dance sequence. The film makers were upset when 'Action Jackson' bombed at the box-office and Prabhas' effort went unnoticed.
Actress Nora Fatehi who was featured in the item song 'Manohari', in "Bahubali" suffered a wardrobe malfunction on the sets. Her top came off in front of the camera and lead actress 'Tamannaah' who was also present on the set, ran to her rescue.
Baahubali: The Beginning (2015) and Baahubali: The Conclusion (2017) were filmed simultaneously. According to the director the sequel of the Bahubali is already 40 percent completed, and wanted to polish the script after getting first chapter's audience reaction.
During the shoot of Dhivara song, the lead actress Tamannaah Bhatia who had no time to go to her caravan and change her dress, had to exchange her clothes at the shooting spot with a cloth against while she's dressing. Rajamouli notified this during the audio launch of the film.