Helmets for the Galactic Empire

Star Wars has become such a cult classic that its characters and costumes are almost instantly recognizable, even to non-fans. One of the most distinctive uniforms is that of the Stormtroopers. And those who want their own do not need to travel to a galaxy far away, but can get one that has been molded on this planet using a vacuum pump from Busch.

Ever since the release of the first film in 1977, Star Wars and the battle between the Empire and the Resistance have been capturing imaginations. The iconic characters and locations have inspired countless items of merchandise that fans cannot wait to get their hands on. Replica costumes are also in high demand – especially Stormtrooper helmets made in the original molds from the first movie.

Classic asymmetry

The helmets for the Stormtroopers, the Empire’s soldiers, were first created using vacuum forming in England in 1976. Back then, there were no CAD programs or CNC machines available to create as precise a mold as could be created today. As a result, the original front and back molds do not quite fit together. Time pressure from the filming schedule meant that the molds were never corrected and maintain an asymmetry to this day. Just like the helmets used in the first movie, the replicas made in these original molds are ever so slightly mismatched – the kind of detail that a dedicated fan appreciates!

Even molding

The helmets are created in a vacuum forming process from acrylonitrile butadiene styrene (ABS), a thermoplastic polymer. The actor’s role as a Stormtrooper meant a lot of stunt work, so a strong material was needed. As the plastic of choice for real-world protective headgear, ABS is ideal. A sheet of ABS is clamped into an open frame and heated until it becomes pliable. On a table below this frame is the mold. Once the forming temperature is reached, the table is raised, and the mold pushed upwards into the plastic sheet, pressing it into its form. As the ABS takes shape over the mold, a vacuum pump from Busch is used. Vacuum ensures that there are no air bubbles and pulls the softened plastic gently over every crevice of the mold to form a uniform layer. Then, the plastic is allowed to cool before the mold is lowered. The Stormtrooper helmet can now have the finishing touches applied, before being sent on to the eagerly awaiting fan.