Girls With Star Wars Universe Imperial Stormtroopers

The troopers' most distinctive equipment is their white battle armor, inherited from their time as clone troopers. The complete armor set completely encases the body and typically has no individually distinguishing marking (in contrast to the clone trooper armor, which typically had various colorings to denote rank or unit, stormtrooper armor has no rank affiliation).
Liz Moore and Nick Pemberton sculpted designs for the helmet. Their designs were based on conceptual drawings by Ralph McQuarrie.
The armor pieces of the costume were also designed from conceptual drawings by Ralph McQuarrie. Brian Muir, who was also responsible for sculpting Darth Vader, sculpted armor pieces for the stormtrooper costume in the Art Department at Elstree Studios. The suit was moulded and initially cast in plaster. Then Brian sharpened the detail at the plaster stage. The plaster casts were then remoulded and cast in fibreglass to use as the "tools" for vacuum forming process. Suits were produced in house by Tashy Baines, the resident vacuum former, but then a problem developed with the machine.
As Shepperton Design Studios had already been used to vacuum form the helmets, the fibreglass moulds for the armour were then sent to them for vacuum forming the suits.