Defender
The Defender Helmet was created by Andrew Ainsworth at Shepperton Design Studios as part of the studio's continuing tradition of handcrafted prop making. Drawing upon the same vacuum forming techniques and practical manufacturing methods used during the production of the original Star Wars costumes in 1976, the helmet reflects the distinctive style and craftsmanship that became synonymous with Shepperton Design Studios.
Manufactured from high-impact polystyrene (HIPS), each helmet is vacuum formed, hand trimmed, assembled and finished using traditional workshop techniques. As with Andrew's earlier work, the handmade production process ensures that every helmet possesses its own subtle variations, preserving the character and individuality associated with hand-built props.
Combining classic production methods with an original design, the Defender Helmet represents the continuation of Andrew Ainsworth's legacy beyond the original film productions. It stands as an example of British practical prop making, showcasing the skills and manufacturing techniques that have defined Shepperton Design Studios for decades.
REBEL
“VISOR SIGNIFICANCE...”
John Mollo asked Andrew to produce three more helmets for the Rebel troops. They were to have various visor types which signified their position in the fighting force against the Empire. Appearing in large numbers for wide screen action shots and in the final medal Ceremony.
GREY
“FOR THE REBELS ONLY...”
These helmets were made from light grey ABS material to identify them as Rebel troops and not part of the white Stormtrooper brigade.
SCOOP
“A NATURAL DEFENSE...”
The sweeping long back scoop formed an extended protection over the back of the head. The helmet back was made using a free formed parabolic shape that Andrew manipulated on the vacuum forming machine, meaning every helmet varied slightly.
VISOr DOWN
“SHIELD ENGAGED...”
The visor on this helmet is in the down defensive position for ultimate protection. The visor was made from translucent grey Acrylic and was fixed down below the forehead cap.