D'Souza also enlisted actors Sanjay Dutt, Zayed Khan, Lara Dutt, and Katrina Kaif. "Blue has a immense budget" at 100-150 crores. It is supposed to have an international appeal. To achieve this, D'Souza enlisted the help of Australian pop icon Kylie Minogue. Minogue will be seen along Kumar in at least one of the films songs. The song is composed by Oscar winning artist A.R. Rahman and choreography is done by Farah Khan.

For "Blue" Hollywood technicians were called in. The international technician crew consisting of Nickolette Skarlatos and Clarabelle Saldanha has worked on the film; their last film was the international blockbuster "Transformers." In filming underwater scenes, D'Souza uses Pete Zuccarini. James Bomalick, who worked in Indiana Jones, choreographs the action sequences.

Filming on the set was a bit scary, one scene called for Sanjay Dutt, Akshay Kumar, and Zayed Khan to be surrounded by 40 sharks. According to D'Souza, "We had shark handlers present on the shoot to make sure that nothing untoward happened. But it was a risky business. Everyone who was around knew that these were living, breathing sharks and that it was their turf." Akshay had to receive special deep sea diving training in Thailand because he wanted to do his own stunts.

Other fears on the set came from Lara Dutt. Dutt has a fear of being underwater, however co-star Kumar helped ease her fears. Yes, Akshay's natural sporty spirit is highly contagious. And it did help me to take the plunge," says Dutt.