Girls With Star Wars Universe Imperial Stormtroopers

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.
By the end of production, two different helmets were produced; one for the common stunt trooper and a second design for closeups. Fifty stunt helmets were produced in white-painted HDPE and six hero helmets were produced in white ABS plastic. Besides the material used, the two designs can be differentiated by differences in the eyes, the ears, and the mouth area.