Ramayana costume designer recalls rush to deliver Ranbir Kapoor's armor
Ajay Kumar opens up about the immense craftsmanship, material hurdles, and tight deadlines involved in creating Ranbir Kapoor's armor for Nitesh Tiwari's upcoming cinematic adaptation.
Published 9 November 2026
Crafting the Visual World of Ramayana
The massive cinematic undertaking titled Ramayana: Part 1 has drawn immense attention for its scale, detailed research, and intricate technical planning. Directed by filmmaker Nitesh Tiwari, the production relies heavily on authentic craftsmanship to recreate a legendary epic universe.
Bringing this vision to life required a meticulous collaboration between the acting talent and the behind-the-scenes technical crews. Every costume piece was subjected to rigorous scrutiny to ensure it fit the historical and mythological aesthetic envisioned by the director.
Ajay Kumar Confronts His Biggest Challenge
Costume and armor designer Ajay Kumar recently shared insights into the grueling process of fabricating the princely garments worn by the lead character during the narrative's first half.
Although Kumar boasts a fifteen-year background in the industry, tackling specialized armor construction proved to be an entirely different hurdle. Transforming initial heavy prototypes into sleek, wearable pieces tested his professional limits.
Overcoming Material and Thickness Hurdles
The primary obstacle lay in modifying the thickness of the wearable gear. While initial sample creations measured between eight to ten millimeters thick, the final required specifications demanded a much thinner profile of two to four millimeters.
Achieving this balance using rubber material required a painstaking two-week manufacturing window. The technical limitations pushed the design team to innovate rapidly under intense pressure.
Ranbir Kapoor's Direct Feedback
Actor Ranbir Kapoor personally evaluated the initial prototypes and offered constructive suggestions to improve the final look. He requested a more refined silhouette that hugged the skin closely instead of flaring outward.
The star specifically asked that the pieces stay well away from his shoulder and neckline areas. Similar adjustments were subsequently requested by co-star Ravie Dubey, who portrays Lakshman in the feature.
A Race Against Time in the Vanity
With critical adjustments demanded by the lead actor, Kumar faced a punishing turnaround window of only two days to execute the alterations. The frantic schedule culminated in a high-stakes delivery happening merely sixty minutes before filming began.
Entering the star's vanity room, the nervous designer requested a trial fitting. He understood that the actor's comfort and emotional connection to the character hinged entirely on the execution of these garments.
Actor's Trust Seals the Design
Despite the extreme time crunch, Kapoor maintained steady confidence throughout the process, allowing the creator the space needed to complete the work. Trying on the modified gear, the actor gave an immediate green light.
The successful fitting validated the intense efforts poured into the project. Expressing satisfaction, the lead star confirmed that the designer had captured the precise royal aesthetic required for the role.
An All-Star Cast Enters the Epic
Helmed by Nitesh Tiwari, the sprawling movie boasts an extensive ensemble cast portraying key figures from the epic narrative. Alongside the primary leads, the production features prominent actors in supporting roles.
The stellar lineup includes Sai Pallavi as Sita, Yash as Ravana, Arun Govil as King Dashrath, Indira Krishnan as Kaushalya, Lara Dutta as Kaikeyi, Sheeba Chaddha as Manthara, Rakul Preet Singh as Surpanakha, and Kajal Aggarwal as Mandodari.
News Overview
Costume designer Ajay Kumar recently discussed the demanding process of creating Ranbir Kapoor's armor for the upcoming film directed by Nitesh Tiwari. After overcoming material hurdles and incorporating the actor's feedback on thickness and fit, Kumar successfully delivered the final gear just an hour before the shoot.
Key facts
- Ajay Kumar designed the armor for Ranbir Kapoor in Ramayana: Part 1.
- Nitesh Tiwari is the director of Ramayana: Part 1.
- Ranbir Kapoor plays Lord Rama in the film.
- Yash plays Ravana in the film.
- Sai Pallavi plays Sita in the film.
- Ravie Dubey plays Laxman in the film.
- Arun Govil plays King Dashrath in the film.
- Indira Krishnan plays Kaushalya in the film.
- Lara Dutta plays Kaikeyi in the film.
- Sheeba Chaddha plays Manthara in the film.
- Rakul Preet Singh plays Surpanakha in the film.
- Kajal Aggarwal plays Mandodari in the film.