More than a decade after its release, Ashutosh Gowariker’s 2008 historical epic 'Jodhaa Akbar' continues to be remembered for its visual scale — particularly its opulent costumes and jewellery. Now, costume designer Neeta Lulla has revealed the extraordinary security measures taken to safeguard the precious ornaments worn by Aishwarya Rai Bachchan in the film.

400 kg of gold jewellery for Jodhaa

Aishwarya Rai’s portrayal of Rajput princess Jodhaa was defined by intricately designed costumes inspired by Rajput and Mughal aesthetics. According to Neeta Lulla, the jewellery alone weighed nearly 400 kg and took over 600 days to craft.

In a recent interview with NDTV, Lulla said five security guards were deployed exclusively to monitor the jewellery room during filming.

“There were around 5 security guards manning the jewellery room. It was noted down, given to the actor, then taken back, and then again relisted and given back,” she said.

The strict protocol reflected both the value and craftsmanship of the ornaments created for the period drama.

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Panic over a missing bead

Lulla also recounted a moment on the 'Jodhaa Akbar' set when the team feared a major loss.

“I remember a funny anecdote when a little bead fell off one of the earrings. The security guard came running to me and said that something had been lost. We all held our breath and asked what had been lost, so he said that a bead had gotten lost. Then, we took a sigh of relief. Everyone buzzed with walkie-talkies and panicked when we thought that a jewellery piece was lost. Everyone came running,” she said. Everyone had panicked, thinking a jewellery piece was lost. Walkie-talkies were buzzing, and people rushed in immediately.”

The incident underscored the scale of investment and vigilance surrounding the film’s costume department.

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Hrithik Roshan’s Mughal armour

While Aishwarya Rai’s regal look drew attention, Hrithik Roshan’s transformation into Mughal emperor Jalaluddin Mohammad Akbar also demanded extensive costume detailing.

The actor wore heavy armour for battle sequences, designed to match the grandeur of the era. Lulla said she expected discomfort complaints but was surprised by Roshan’s precision.

“Contrary to what I thought, Hrithik would come to me and complain about how much weight I was putting on him, with the armour, etc. But he was very cooperative. On set, this man noticed that his armhole was a quarter inch bigger than the other one. I was shocked, even though I hadn’t noticed that. He is that attentive. He was wearing the armour and asked me to chisel it without taking it off,” she said.

A benchmark for period drama costumes

'Jodhaa Akbar' remains a reference point for historical costume design in Bollywood, with its elaborate jewellery, handcrafted textiles and detailed armour contributing significantly to the film’s authenticity and visual impact.

Neeta Lulla, who designed the costumes for the film, is a four-time National Film Award winner for Best Costume Design.