After The Texas Chainsaw Massacre: The Beginning's profitable, but disappointing box office numbers, Platinum Dunes and New Line had no interest in producing another film in their remake franchise. As a result, the rights reverted to Bob Kuhn and Kim Henkel, who entertained offers to produce new films in the franchise. In late 2009, Twisted Pictures and Lionsgate purchased the rights to the franchise, and signed a deal to produce several new films (the number of films planned ranged from five to seven). More details emerged in early 2011 when Lionsgate partnered with Nu Image films to help produce the film, which was going to be shot in 3D. 3D was, of course, the big trend at the time. Following the box office success of Avatar, films such as Clash of the Titans began converting to 3D in post-production and experienced a box office bump as a result (although such shoddy 3D conversions would ultimately lead to major audience fatigue with 3D due to the poor quality). After seeing that 3D meant big business, many films began being shot and released in the format, such as the horror comedy Piranha 3D.
John Luessenhop was hired to direct, having just come off of the relative success of the Matt Dillon-starring armoured truck heist film Takers (not to be confused with the other Matt Dillion-starring armoured truck heist film that had come out the year before, Nimród Antal's Armored). It was announced that the new film would be a direct sequel to the original film and would ignore the events of the sequels and remake. Debra Sullivan and freaking Adam Marcus (most famous for being the writer and director of the flat-out worst Friday the 13th film, Jason Goes to Hell) were brought on board to write the script for the film. According to Adam Marcus, the original intent was to explore Leatherface's relationship to his family and to fill out some mythology for him, much like what he did with Jason Voorhees (and failed spectacularly at, which I can't stress enough). He also intended to set the film in the '90s (in a cheeky bit of meta-text, it was intended to be set around the release date of Jason Goes to Hell). The film was also designed as more of a monster movie, rather than a slasher film, which would give Texas Chainsaw 3D a different sort of feel within its franchise. However, after Kirsten Elms and Lussenhop took the script for rewrites, someone high up in the production decided to change the film's setting to the modern day at the last minute, even though the film had already been cast with characters aged for a '90s setting. As a result, the actors are all inexplicably 20 years too young, a major plot whole which basically every review of the film will point out. Presumably, the person in charge of that decision just assumed that audiences wouldn't notice or care, but it's really obvious and dumb when you watch the film.
Speaking of the cast, Texas Chainsaw 3D brought back a number of classic Chainsaw cast members for cameo roles. Most notably, Marilyn Burns and Gunnar Hansen both returned to play Verna Sawyer-Carson and Boss Sawyer, respectively. This was Hansen's last film appearance before his death in 2015, and one of Burns' last roles before her death in 2014. Bill Moseley also returned to play Drayton Sawyer in the film's opening scene, playing tribute to the late Jim Siedow who had died in 2003. John Dugan was the only returning actor to reprise his role from the original film, having played Grandpa Sawyer way back in 1974. As for the new cast, the gorgeous Alexandria Daddario was cast in the lead role of Heather Miller, while the role of Leatherface went to Dan Yeager in his first major role. Notably, Scott Eastwood was also cast as a local policeman named Carl. As for the other leads, rapper Trey Songz was cast as Ryan, Tania Raymond as Nikki, Keram Malicki-Sánchez as Kenny and Shaun Sipos as the hitchhiker Darryl. Other notable cast included Paul Rae as the villainous Mayor Burt Hartman and Thom Barry as the not-so-subtly named Sheriff Hooper.
Filming began on July 18, 2011 in Shreveport, Louisiana during a traditional Chainsaw heatwave and would continue for six weeks. A big deal was made about the crew recreating the Sawyer house, using the original film to try to match all of the details as closely as possible. It was supposedly so accurate that Gunnar Hansen's only note was to move a chicken cage over a few feet when he arrived on set. Luessenhop shot the film using state-of-the-art Red Epic cameras. The film was also shot on a very low budget (around $11 million), which made production particularly difficult at times and forced the cast and crew to work on a 24-hour schedule towards the end to get everything completed in time. The film was originally scheduled to release in October but was pushed back to January 4, 2013 by the studio for, according to Luessenhop, "stictly business decisions". This delay may have been, in part, because when the film was submitted to the MPAA, it received an NC-17 rating for extreme violence and had to be re-cut.