Cast Away

In a 2017 Actor Roundtable with The Hollywood Reporter, Tom Hanks stated[3]

I made Cast Away because I wanted to examine the concept of four years of hopelessness, in which you have none of the requirements for living — food, water, shelter, fire and company. But it took us six years to put together the alliance that would actually examine that. I only had a third of it, and Bill Broyles only had a third of it, until Bob Zemeckis comes along and provided that other third. I had that original idea. I was reading an article about FedEx, and I realized that 747s filled with packages fly across the Pacific three times a day. And I just thought, "What happens if that goes down?"

— Tom Hanks in 2017[3]

The film's shooting occurred between 1998 and 2000, but was not shot consecutively. Hanks gained 50 pounds (23 kg) during pre-production, for the purpose of making his transformation more dramatic. After a majority of the film was shot, production was halted for a year so that he could lose the weight and grow his hair and beard to look like he had been living on the island for years. Another four-month production halt preceded the filming of the final return scenes. During the year-long hiatus, Zemeckis used the same film crew to make another film, What Lies Beneath.[2]

Cast Away was filmed on Monuriki, one of the Mamanuca Islands in Fiji.[4] It is in a subgroup of the Mamanuca archipelago, which is sited off the coast of Viti Levu, Fiji's largest island. The island became a tourist attraction following the film's release. After Chuck's return, it is identified by Kelly as being "about 600 miles south of the Cook Islands," but there is actually no land between the southernmost Cook Islands of Mangaia and Antarctica.

The film essentially begins and ends in the same location, on the Arrington Ranch in the Texas Panhandle south of the city of Canadian, Texas.[5]

The film's minimal score was composed and conducted by Alan Silvestri for which he won a Grammy Award in 2002. The film's soundtrack is most notable for its lack of score and creature sound effects (such as bird song or insect sounds) while Chuck is on the island, which is intended to reinforce the feeling of isolation.[6] Cast Away contains no original musical score until Chuck escapes the island. However, there is a Russian choral piece heard near the start of the film that was not composed or even recorded by Silvestri, so it does not appear on the film's soundtrack list. It is a traditional Russian song written by Lev Knipper called "Oh, My Field" ("Polyushko, Polye") and it is available on various collections of Red Army hymns.

The official soundtrack CD is an anthology of musical pieces from all films up to that point directed by Zemeckis and scored by Silvestri. The only track from Cast Away itself is the theme from the end credits.[7]

FedEx provided access to their facilities (Memphis, Los Angeles, and Moscow) as well as airplanes, trucks, uniforms, and logistical support. A team of FedEx marketers oversaw production through more than two years of filming.[8] FedEx CEO Fred Smith made an appearance as himself for the scene where Chuck is welcomed back, which was filmed on location at FedEx's home facilities in Memphis, Tennessee. The idea of a story based on a FedEx plane crashing gave the company "a heart attack at first," but the overall story was seen as positive. FedEx, which paid no money for product placement in the film,[9] saw an increase in brand awareness in Asia and Europe following the film's release.[10]

Wilson the volleyball

In the film, Wilson the volleyball serves as Chuck Noland's personified friend and only companion during the four years that Noland spends alone on a deserted island.[11][12][13] Named after the volleyball's manufacturer, Wilson Sporting Goods, the character was created by screenwriter William Broyles, Jr. While researching for the film, he consulted with professional survival experts, and then chose to deliberately strand himself for one week on an isolated beach in the Gulf of California, to force himself to search for water and food, and obtain his own shelter. During this time, a volleyball washed up on shore. This was the inspiration for the film's inanimate companion. From a screenwriting point of view, Wilson also serves to realistically allow dialogue in a one-person-only situation.[14][15]

One of the original volleyball props was sold at auction for $18,500 to the ex-CEO of FedEx Office, Ken May. At the time of the film's release, Wilson launched its own joint promotion centered on the fact that one of its products was "co-starring" with Tom Hanks. Wilson manufactured a volleyball with a reproduction of the bloodied handprint face on one side. It was sold for a limited time during the film's initial release and continues to be offered on the company's website.[16]

A comic reference to Wilson's name being derived from the volleyball manufacturer's is made in the movie, when Chuck tells Wilson "A funny thing" - his dentist's name happens to be Spalding (referring to sporting goods manufacturer Spalding, a competitor of Wilson's).