The helmet, which was created using an alloy of durasteel, plasteel, and obsidian, created Vader's menacing growl due to his natural voice being very weak from vocal-cord damage, and contained neural needles that painfully connected with the top of Vader's skull and spine, to form one interconnected unit.

The mask is the most intricate part of the helmet. This is where Vader's respiratory system lives, helping him intake and vent air to his sensitive lungs. The lenses aid Vader's weakened vision, calibrating colors to accommodate his damaged eyesight and enhancing his field of view.

A life cast was made of David Prowse to ensure it would fit the hulking actor properly. Clay was then used to sculpt the facial mask over the life cast of Prowse's head; the mask was molded and cast into a plaster master, and then the helmet was sculpted to fit the mask.

Once you're wearing the helmet, three different modes allow you to adjust the pitch of your voice! Make actual Darth Vader breathing sounds, or hear real phrases spoken by Lord Vader in the movies! Best of all, activate the third mode and speak into the helmet¿ your voice will sound just like Darth Vader's!

Nazi Helmets Inspired Darth Vader's Headgear Costume designer John Mollo took it from there, fusing elements of various real-life uniforms associated with war and evil. To design Vader's infamous black helmet, Mollo looked to the black, shiny headgear Nazis wore during WWII.

Brian Muir (born 15 April 1952) is a British sculptor who most famously created Darth Vader's helmet and armour using Ralph McQuarrie's design.

The suit contains a mobile life-support system, and from a careful analysis of Episodes IV-VI, we have concluded that it functions as an advanced bi-level positive airway pressure (BPAP) system that supports Darth Vader's intrinsic breathing both during in- and expiration, while preventing airway collapse, and ...

Most notably, Vader's helmet can be traced back to samurai gear, especially Masamune's iconic black armor. Masamune wore a rimmed helmet with an extended shield around the back and sides of his head, much like the helmet Vader is known for.

It's a deep and menacing voice that has become synonymous with the character himself. From the first time that audiences heard Darth Vader speak in the original Star Wars film, they were captivated by the power and intensity of the voice.

After his battle with Obi-Wan on Mustafar, Anakin's vocal cords and lungs were scorched by lava. Due to this, Darth Vader had to wear an iron lung with tubes connected to a voice synthesizer inside his mask. Using this technology, Darth Vader could speak with a deep, synthetic voice.

Darth Vader's iconic suit was inspired by the armor and helmets of Feudal Japanese Samurai, whose adherence to bushido hints at Vader's redemption.

Although Jedi Knights were more heavily inspired by samurai than Sith Lords, Darth Vader's suit design was intentionally patterned after samurai armor and his redemptive sacrifice creates an additional parallel to the bushido code's seppuku.

Ben Burtt is the sound designer for the "Star Wars" movies. And to get Vader's mechanical breathing, Burtt went to a California dive shop, jammed a small microphone into a scuba regulator and started sucking air. Mr. BEN BURTT (Sound Designer): When you breathe through it you could hear the valve opening and closing.