Production Notes
The film's producers include Dino De Laurentiis, Martha, his second wife, and Raffaella, his daughter by his first wife. Raffaella suggested director Doug Lefler due to his work on Dragonheart: A New Beginning, which she produced. Filming took place in Tunisia and at Spiš Castle in eastern Slovakia in 2005.
Valerio Massimo Manfredi helped adapt his novel to the screen, also acting as historical consultant. In an interview he states at least four hours of footage was shot but ultimately shortened or cut, including scenes of the heroes' journey through the Alps and the English Channel.
For the role of Aurelius, executive producer Harvey Weinstein suggested Colin Firth, known for playing Fitzwilliam Darcy in Pride and Prejudice (1995) and more recently, Mark Darcy in the Bridget Jones films. Firth accepted the role due to the story, which he liked, and that it was very different from previous roles.
Thomas Sangster (Romulus) was one of the last to be cast. He had previously worked with Firth in Love Actually (2003) and Nanny McPhee (2006), and their familiarity with each other benefited both.
Sir Ben Kingsley was cast as Ambrosinus/Merlin after one meeting with Lefler. Kingsley was drawn to the mystique of the character, whom Lefler describes as a "warrior shaman". Kingsley also found the story interesting.
Aishwarya Rai was cast as Mira after the filmmakers decided "somebody that had a rare beauty... who could move very well", in Lefler's words, was ideal for the role. Lefler touted Rai's training in dance as an asset for her fight scenes. Like Firth, Rai took the role as a change of pace from her previous work.
The film's costumes were designed by Paolo Scalabrino, who had worked on Gangs of New York and Troy.
Lefler wanted each character to have a unique fighting style. Richard Ryan served as the film's sword master, helping him plan the fight scenes; he had worked on Troy and would work on Stardust as such.
The film's score was composed by Patrick Doyle.
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