Lucasfilm Ltd. © 2019 Lucasfilm Ltd. All Rights Reserved.
When I set eyes on the original helmet from The Mandalorian™ in person, my first thought was: “Wow, that helmet wasn’t as I expected!”
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Having closely studied the original Boba Fett™ helmets, I can appreciate why Jeremy Bulloch dubbed him “Bucket head.” Boba Fett and Jango Fett™'s helmets were similar in size, where The Mandalorian™'s helmet is more compact and fitted.
Forty years past Boba Fett’s creation, we are clearly in a different time and this new helmet serves a different purpose. The Mandalorian’s helmet, as with the entire costume, is built for action and stunts. Everything is tight and well fitted. There is no bucket feel or bobblehead here. This helmet is meant to move with you and be purely functional.
Pedro Pascal is The Mandalorian in the Disney+ series THE MANDALORIAN. Lucasfilm Ltd. © 2019 Lucasfilm Ltd. All Rights Reserved.
My second thought was regarding the finish, recognizing that it was going to be one of our biggest challenges.
At first, the helmet’s paintwork seems quite simple—just a pewter finish with some weathering—but upon closer inspection, this isn’t true at all. Just for comparison Captain Phasma™’s helmet has a chrome finish and Jango Fett’s helmet color was a result of being cold cast with aluminum powder. The Mandalorian’s helmet is neither! It is unique and quite complicated. First, because of the way it was painted, it changes its color contingent upon different lighting conditions. Second, don’t let the initial “one-note metallic” finish fool you! There is an incredible amount of subtle intricacy, not seen in other paint jobs, with clever shifts in tonality—somewhat mimicking the contouring seen in the makeup industry.
Pedro Pascal is The Mandalorian in the Disney+ series THE MANDALORIAN. François Duhamel. © 2018 Lucasfilm Ltd. & ™. All Rights Reserved.
We learned the exact paint process the production team used to paint the original screen-used helmets. Even though we knew how the helmets were painted and detailed it still took our development team a few weeks to settle upon a paint process we can implement for mass production which replicates the beauty and subtle tone shifting nature of the original helmets. To perfect our finishing process we painted our prototypes side-by-side with an original screen-used helmet which allowed us to instantly compare our paintwork directly to the original piece and make adjustments as needed. Once our factory paint and finishing processes were authenticated against the real screen-used helmet, our research team directly guided our artists as they hand-painted and weathered each helmet based on the same multi-stepped techniques used to create the originals. There was a lot of cleverness poured into replicating the paint finish and I am proud that we were able to provide this artisan touch to our collectors in this helmet.
Helmets ready for the intricate painting process and helmets ready for final touches. © 2019 ANOVOS & ™. All Rights Reserved.
Boba Fett will always have a cult following and this new character, The Mandalorian, is awesome in his own right and will likely find a similar fandom. His look takes advantage of all the latest technologies in digital printing as well as modern paints. He is more streamlined, and his overall design is far more agile. He is the future and a character worthy to be called The Mandalorian.
ANOVOS finished helmet. © 2019 ANOVOS & ™. All Rights Reserved.
© & ™ Lucasfilm Ltd.