Legendary Darth Vader Mask Custom Prototyped for Filming with Roland DG SRP Technology

Roland DG SRP® desktop milling devices have gone to the “Dark Side,” prototyping the Darth Vader mask with better fit and symmetry for Revenge of the Sith, Star Wars Episode III.

Industrial Light & Magic, the studio famous for its brilliant special effects, used a MDX-20 to custom make the mask especially for actor Hayden Christensen’s head. “This is the first time we’ve ever seen a symmetrical Darth Vader,” said Ivo Coveney, ILM Studio costume props supervisor.

“We are thrilled that ILM used the MDX-20 for this menacing and legendary mask. It’s a huge testament to the quality of Subtractive Rapid Prototyping technology.”

Capable of 3D scanning and milling, the MDX-20 helped ILM in several ways. After the studio created a life-size mold of Christiansen’s head, it fitted the desktop device with its touch probe sensor and scanned one side of the face. They created the other identical side by simply reversing the digital file in the software. Then, they attached the MDX-20’s spindle tip to mill both the right and left sides of the mask.

"We are thrilled that ILM used the MDX-20 for this menacing and legendary mask,” said David Olson, Roland DG ASD business development manager. “It’s a huge testament to the quality of Subtractive Rapid Prototyping technology.”