Andrew Ainsworth is the prop-maker who created the original Stormtrooper armour for A New Hope. He was in the news recently when he won a court ruling allowing him to sell replica costumes form the original moulds, so you might have read about him. Here he takes us through the original process of how these helmets were made. Just for the record, I still want a vaccum-forming machine.
It appears there is a disturbance in the force. After posting this original article, I was contacted by a chap going by the name of "Demain" (http://damianvila.com) who is one ot the 501st Legion. If you've not heard of these guys, they are the organisation comprised of people who own their own sets of Stormtrooper armour.
It turns out that Andrew Ainsworth is actually inflating his role somewhat by taking credit for the creation of the original trooper armour and that it was actually created by two different people. It turns out that the helmet was sculpted by the late Liz Moore and the rest of the armour was sculpted by Mr Brian Muir (who also did Darth Vader's original helmet). Here he is sculpting the Death Star Droid from the Jawa Sandcrawler in A New Hope.
You might recognise the scene below as part of the space-jockey set from Alien that Brian worked on with Peter Voysey.
Liz also worked on the Korova Milk Bar from Stanley Kubrick's "A Clockwork Orange" besides sculpting some other strange creatures you can see below.
Like much of the rest of the original Star Wars, scenes like the one below have Brian and Liz's work all over them.