Andrew Ainsworth is a Model Maker who recently won a court battle against Lucasfilm to continue to produce Star Wars helmets using the tools he made to produce the originals for the films. His YouTube channel goes into great detail to show you how these are made. Although this is probably quite dull for most people I found it amazing how every piece is a relatively simple vacformed part. Great work.
thanks john :http://johncaswelldesign.blogspot.com/