Armour
The Stormtrooper Armour was created for Star Wars: Episode IV - A New Hope in 1976 and manufactured by Andrew Ainsworth at Shepperton Design Studios. Produced using vacuum forming techniques, each suit consisted of multiple high-impact polystyrene (HIPS) components that were hand trimmed, assembled and fitted to the performer. The armour was designed to balance the visual requirements of the production with the practical demands of filming.
Rather than being manufactured to a single standard, each suit was individually finished by hand, resulting in subtle variations in trimming, assembly and fit. The armour featured overlapping construction, elastic strapping and press stud fastenings, allowing it to be worn by performers of different sizes while maintaining the distinctive appearance of the Imperial Stormtrooper.
The original Stormtrooper armour has become one of the most recognisable costume designs in cinematic history. Its handcrafted construction, characteristic asymmetry and practical production methods have been extensively documented and studied, with the original 1976 armour serving as the benchmark for authenticity among collectors, historians and prop makers worldwide.
HIGH GLOSS
“A TRADE SECRET...”
The original armour was vacuum formed in HIPS plastic. By increasing the amount of Butadiene (Synthetic rubber) in the mix, Andrew created armour that was flexible enough to withstand rigours of action shots (Vital for the impact of the opening shots of ANH).
Our current production still has the flexible light weight ABS plastic but with a fantastic modern tweak of a high gloss “acrylic capped” surface. This stops yellowing and keeps your armour in pristine condition.
CHEST
“ADAPTABLE ARMOUR...”
Todays armour can be adapted to suit modern day Troopers, much like it was back in the70’s. Adjustable straps mounted on the inside of the chest allow for both width adjustment and shoulder straps do the same for height adjustment.
TORSO
“HOLDING IT ALL TOGETHER...”
The abdominal front and lower back have adjustable straps with the amo belt holding all parts firmly in place. Upper arms are strapped to the shoulders but the forearms are self supporting and have the original detail of 12 divots on the right & only 11 on the left.
THIGH
“STAND STILL & DON’T CRY...”
Lucas commandeered an actor dressed in the armour to stand still whilst Andrew cut the thighs and calves in situ with a circular saw – brave lad!
The calves and thighs were “re-tooled” several times to create enough movement and so as per the originals these grew a little asymmetric - which is still the case today. The thighs are suspended from the abdominal front but the calves are self supporting and so easily move in relation to each other.
KNEES
“CAN THEY RUN?..”
Movement required at the knees to accommodate different hight actors and the general biomechanics of a running Trooper was essential. Andrew created an additional “ammo-wrap” around the right leg and a diamond knee cap moulding on the left. This served to disguise the gap but also added some medievil flair!
BOOT
“THE CHELSEA TROOPER ...”
The original Stormtrooper wore white “Chelsea Boots” and we manufacture the very same today. These have supple calf leather uppers with no seam and leather soles with an Ethafoam sandwich for insulation comfort. The Stormtrooper emblem is embossed on the sole and inside our trademark, “Shepperton Design Studios”.