Most of you know that Darth Vader's helmet was, unlike a motorcycle helmet, comprised of two pieces. Design studies written on the subject indicated that he refused to wear a chin strap, necessitating a two-piece design; were his helmet and facemask only one piece, the opening would have to be larger in order to get it on, and a chin strap would be required to take up the slack once in place.
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While Imperial designers couldn't crack that problem, an Australian company called Vozz Helmets has. That's right, they've come up with a one-piece helmet and facemask, fully enclosed, no chin strap. Here's how they did it:
In the video below, a rare Australian Sith explains the user benefits of the Vozz design:
The helmet is project to start shipping next month. In the meantime, here is some highly relevant footage revealing why James Earl Jones' voice was used for Darth Vader, rather than the voice of the German actor who actually portrayed Vader on film: