When Attack of the Clones was in pre-production George Lucas took the bold decision to have all of the clone troopers seen in the movie created in ILM’s computers. This afforded greater flexibility while shooting, limiting the arduous, time-consuming task of co-ordinating and directing hundreds of expensive extras in take after take. It also allowed more creativity and control over the clone trooper shots. So, for the first time ever on a Star Wars film, the Empire’s nascent foot soldiers never actually existed as physical, three dimensional helmets or costumes. Instead they were created entirely within the confines of the ILM hard drives.
To denote the different ranks within the Clone army, different colored helmet paint treatments and details were added to distinguish ranking officers from the foot soldiers. In Attack of the Clones the deep color red denotes the rank of Captain.
Using digital files supplied by the Lucasfilm Archives, our engineers created an exact 3-D model of the “digital” clone trooper helmet, which we output as a SLA (Stereolithography) model and sent to our factory in China. This was used as the mold master for all of the production helmets ensuring that all of the Clones would look the same.