Meet China’s Master of Star Wars Costumes

Originally from Belgium, Vincent Rondia first came to China in 1999, driven by a childhood dream to explore Asia.

He has worked as a creative director in Changchun, as the head of a private design school in Beijing, and is currently based in Shanghai.

Along the way, and under the call sign MrV, he developed a passion for creating life-size replicas of sci-fi props and costumes, including 67 from the Star Wars universe.

In honor of May the Fourth—and in the hope of better understanding the Force and wielding its power for good—we caught up with him to find out more.

Vincent Rondia with Stormtrooper bust

When did you first get into Star Wars?
I first engaged with Star Wars when I was six, 44 years ago, by watching The Empire Strikes Back at the local movie theater upon its release.

I was immediately blown away by the visuals, the unique characters, and their costumes. The spaceships were incredible, and there was enough action to keep me engaged, while the story itself was not overly complicated.

It was the classic good versus evil narrative, much like every story you encounter at that age, making it easy for me to get into. My passion for Star Wars was solidified a few years later with Return of the Jedi. 

By then, I sensed that this was going to be a lifelong fandom for me. I was deeply immersed in the universe—reading the books, playing with toys, reenacting scenes, and even creating my own stories during playtime. It was truly a unique experience in my life.

Over time, Star Wars has become an integral part of everything I do. It has served as a catalyst for learning; I’ve studied design through its lens.

The stories and the way the fandom engages with them have helped me understand people and make sense of things that don’t immediately seem clear.

Moreover, it provides a moment of escapism, allowing me to immerse myself in a completely different universe and momentarily forget about what’s happening in my own life.

How did you get into making Star Wars costumes?
I started working on my first costume in 2009 and completed it in 2012—Baron Fel, the 181st TIE Fighter Pilot from the comic book Rogue Squadron.

It took me three years to put together because I had absolutely no idea how to do it, what was expected, where to source materials, or how to assemble it. It was a complete learning process, and everything that could go wrong did go wrong.

However, it was a lengthy but rewarding experience because I wanted to reconnect with my own fandom in a unique way—something that would provide me with more than just collecting items. I wanted to learn new skills, and this was a great opportunity to do so.

Vincent as Baron Fel, the 181st TIE Fighter Pilot 

I contacted my local chapter of the 501st Legion and spoke with some members while I was gathering pieces. This meant I had to conduct a lot of research on the character I wanted to create.

Research was the essential first step; when you’re working on any design, you need to start with thorough research. I obtained comics featuring the character and analyzed all the pictures to determine what the costume looked like, what accessories were needed, and where to source everything.

Vincent (in the foreground) as Baron Fel at the 2014 Beijing Film Festival

In my efforts, I ended up sourcing some incorrect parts and had to create some of my own with the limited skills I had at the time.

I had to be creative until I met another member of the local garrison; they explained things like glues and paints, and provided me with some crucial dos and don’ts that I still follow today.

As of now, I have built over 67 costumes set in the Star Wars universe, as well as a few from other sci-fi franchises such as the classic Battlestar Galactica Cylon, a Xenomorph, a Planet of the Apes Gorilla Warrior, a visitor from the 1980s V TV show, a Ghostbuster, and an alien from the TV show Resident Alien just to name a few.

Each costume is a highly accurate replica of what is seen on screen.

Vincent as Baron Fel (third from right) with Kathleen Kennedy, President of Lucasfilm

What is the 501st Legion?
The 501st Legion is a global costuming club with chapters, known as Garrisons, in many countries around the world. We are recognized by Lucasfilm as the definitive club for Imperial costumes.

There are approximately 15,000 active members worldwide, and we recreate costumes with the utmost attention to detail, ensuring they are incredibly accurate to what was seen on set and in the films.

The guiding principle of the 501st is that we are the “bad guys doing good.” The 501st is a costuming club, not a collecting club, which means we create these costumes to wear at events and for charitable purposes.

The 501st Legion reporting for Make-A-Wish Foundation duty

In Shanghai, for instance, the club supports organizations like the Make-A-Wish Foundation, blood drives, and various animal shelters. We participate in events to attract attention, engage the community, and raise funds for these charities.

We also take part in Comic-Con and other conventions, appearing at red carpet events, sports events, and concerts where there is a connection to Star Wars.

Recently, we attended Star Wars Celebration in Japan, which occurs every other year and draws around 100,000 visitors over three days. Among them were about 1,000 members of the 501st, all in costume, with some even switching costumes throughout the weekend.

“You will never find a more wretched hive of scum and villainy.”

The largest number of members is located in the United States. The second largest group is in Europe, primarily in Spain, the United Kingdom, and Germany.

We also have a significant presence in Asia and Oceania, including countries such as Singapore, Malaysia, Thailand, Japan, Indonesia, the Philippines, Vietnam, Australia, New Zealand, and of course China.

In China, we have members mainly in Beijing, Shanghai, and Guangzhou, but there are also a few members scattered across various cities.

Although some members may be alone in their locations, they still travel to events when they are held in the big cities.

What has been your favorite costume to make?
I have three costumes that are my favorites. The most recent one is a crossover I created that merges the Mandalorian warrior and Ghostbusters universes, and features sound effects from Ghostbusters integrated with elements from Star Wars.

Mandalorian & Ghostbusters mashup

I really enjoy this mashup because I think it works well visually and conceptually in both universes. I debuted this costume at Star Wars Celebration in Japan last April, and I was pleased to see that many people enjoyed it.

Ghostbusters Proton Pack meets Boba Fett Jetpack

Historically, the first costume I really loved making was my Wookiee. I went through seven different iterations to get it right, as it’s quite a painstaking process to create a proper Wookiee costume.

You can’t just use random materials; the face needs to look authentic so that people can connect with it. The process requires creating a mesh fabric suit and carefully tying hair onto it one strand at a time.

“The face needs to look authentic”—Vincent as a Wookiee

The first Wookiee costume I made took me a year and a half to finish, and I was very proud of it. However, I later decided to make a new version with a technique I had developed to blend the hair better, achieving a more natural look with different colors.

I sold the first one and went on to create six more, each one a beautiful yet challenging costume to wear—to achieve the proper height for the character, I have to wear stilts, which can be uncomfortable and borderline dangerous.

Still, the public absolutely loves this costume, even those who aren’t familiar with Star Wars. I receive a lot of wonderful interactions while wearing it, but it has been a significant learning experience.

I had to work with hair extensions, silicone masks, and even learned how to punch hair into a silicone mask to make it look natural.

Everybody loves a Wookiee 

One costume that I absolutely love is my Zombie Stormtrooper. This costume is so much fun to wear, and it creates incredible interactions with the public. People might be scared at times, but the engagement I experience is unlike any other.

I’ve worn it in countries like China, Japan, Australia, the UK, the United States, and Belgium—and each location has its own unique reactions.

Vincent gets his zombie face on

I had to be creative in making the armor. I started by purchasing standard armor parts and constructing the armor, mimicking a general Stormtrooper’s look.

From there, I creatively destroyed the armor to give it a zombie-like appearance, painting it to closely resemble what a zombie would look like.

I also designed an undersuit to mimic skin that had been burned and bitten, ensuring it looked believable.

I utilized techniques I developed while creating my Xenomorph costume, even incorporating fire to burn plastics and fabrics for a more authentic effect.

I believe I have created one of the best Zombie Stormtroopers in the world; among the few that exist, I’m confident mine is in the top five.

Zombie Stormtrooper creates incredible interactions with the public

What is the most unusual thing you have used to create part of a costume?
When working on a costume, we typically use a variety of materials, including different fabrics, plastic, ABS, and 3D-printed parts.

There is a wide range of materials to choose from, especially when designing a character that wears armor and a helmet.

Leatherwork is also involved, which is quite traditional, such as belts, pouches, and satchels. We do incorporate metal parts as well, which are standard in many costumes.

However, one of the more unusual materials I’ve worked with is yak hair, especially when creating a bust display of Chewbacca; in the original trilogy, the costume was made of yak hair, so I had to source authentic yak hair for this project.

This is very different from the synthetic hair I’ve used to make my own costume. I ordered the yak hair to be woven into a fabric, and the texture and flow of the hair on the body are unique.

For the best results, I had to carefully stitch it onto a mesh suit, which made this process quite distinctive and—admittedly—very expensive.

Vincent with Mark Hamill, AKA Luke Skywalker

You have met Mark Hamill—was that your most special Star Wars moment?
Having my picture taken with Mark Hamill might seem like the most special Star Wars moment, but in reality, my pride stems from having some of my work featured in several productions, including season one of Ahsoka.

What makes it even more special is that my contributions are not just brief cameos; they are used in key scenes throughout the series, and it’s very evident that they are there.

It’s mind-blowing to know that I played a part in that. I admit I was extremely emotional the day I saw my work on screen during a pivotal moment in a clone battle. It reconnected me with the animation from The Clone Wars, which I absolutely loved.

Vincent’s clone boots and gloves, as featured in ‘Ahsoka.’ Screenshot by That’s.

This experience was emotional as it brought back memories of the challenges I faced while working on it during COVID, between lockdowns.

Overall, it was a powerful moment for me, both while watching it and reflecting on the journey of creating.

On the commercial side of things, how does it work—do you make the costumes and then see if anybody is interested in buying them? Or do people commission you to make specific costumes?
I primarily make costumes for characters that I want to play at least once. After completing a full costume, I create a display bust in a 1:1 scale using real clothing and materials, along with the armor parts or mask that completes the character.

Busts on display in Vincent’s studio

I display these costumes at home or in my studio. Sometimes, when people visit, they express their admiration and indicate they would like to buy a costume, which has led me to sell a few.

I also receive requests for commission work. Clients come to me with specific characters and costumes they would like to create, and I explain the process and associated costs. They can then decide if they want to proceed.

At times, I create costumes for myself but later find that I no longer want to wear them. In such cases, I offer them for sale within the costuming and collecting community on Facebook, where others purchase them.

It’s important to note that these are not Halloween costumes you can buy for around RMB200 on Taobao. They are highly accurate replicas of what is worn in movies, requiring significant research to identify the right colors, fabrics, design elements, and materials.

The cost of one such costume can range from RMB7,000 to RMB25,000. Typically, these are not impulse purchases; buyers are often fans or collectors who are willing to invest in something to wear or display.

Is there a costume you love so much you cannot bring yourself to sell it?
No, I don’t worry because I know I can always remake a costume if I need to.

In fact, during the process of creating a costume, I learn a lot. When I finish it, I’m usually very happy with my work.

However, over time, I start to notice things and think that, in hindsight, I could have made it differently or added more details.

This often leads me to consider redoing the costume, which I have done multiple times for several costumes—seven times for my Wookiee costume alone.

Each time, I learn something new, and others benefit from my work by being able to purchase that particular costume.

There are a few pieces that would be very hard for me to part with, like the Wookiee bust; I don’t think I could sell that one because its story is quite unique.

Additionally, my new Ghostbusters Mando holds particular significance, so I wouldn’t let that go either. It’s not that I couldn’t make them again, but they have special meaning for me.

Vincent’s studio

If you could be a character from the films series, who would it be?
It’s a very difficult question to answer because I am a fan. I would be thrilled to play any character, even a background character with no lines.

I would absolutely jump at the opportunity to be part of it, so I’m not discriminating against any character per se.

However, I don’t think I would want to be any of the main iconic characters from the original trilogy. Instead, I would enjoy exploring more ambiguous identities within that universe—characters who are not entirely good or bad, who are still searching for themselves and blurring the lines.

That’s how I see myself. Given the current release cycle of TV shows, I believe Cassian Andor would be a great character for me to portray. Or perhaps his droid. I absolutely love that particular character.

Cassian Andor and his droid. Screenshot by That’s.

Tell us about the interview series you conducted with fellow fans?
These interviews are a result of my work and my reputation within the community. I have access to many individuals that other members may not be able to connect with.

These individuals are significant figures in the community; some are not only members of the fandom but also actors who have appeared in various series.

Others are fellow prop makers who make costuming possible by creating parts that would otherwise be unattainable. Without their contributions, our community would not exist as it does today. For instance, I am fortunate to know Brian Muir, the original sculptor of Darth Vader’s armor.

Brian Muir, the original sculptor of Darth Vader’s armor, and part of Vincent’s PhD interview series

I initially viewed these interviews as part of my PhD research, in which I use my involvement in the Star Wars fandom as a case study to explore the religious characteristics of fandom in general.

However, everyone who has gone through this process can attest to how ones perspective usually evolves away from what they originally envisioned—my PhD has taken a different direction than I initially anticipated.

Nonetheless, I still believe these interviews are crucial for helping the community understand, reflect on, and recognize that much of what we do is rooted in shared experiences.

Even though we come from different eras of fandom and diverse backgrounds in terms of culture, gender, beliefs, nationality, and language, the experiences that drive us are surprisingly similar.

I thought there was great value in sharing these stories so that the community can realize that their unique experiences in Star Wars are validated.

While each person’s journey is unique, there are enough parallels in our stories to remind everyone that they are not alone.

Which are your other favorite sci-fi canons to branch out into?
I am a huge sci-fi aficionado, which means I absolutely love everything related to the genre.

As I mentioned earlier, I have created costumes for a Xenomorph, a Cylon, a classic Planet of the Apes Gorilla Warrior, and more.

If I see a costume that looks stunning or resonates with a particular character, I’m likely to start creating it, provided I have the time and resources.

One costume I really want to make is a warrior from House Atreides in Dune. I’m not referring to the desert stillsuits, but the actual combat suits worn by the Atreides.

I have the files to 3D print the armor, and I’ve already sketched out the jumpsuit that goes along with it. I’ve also identified the gloves used in the production as well as the boots. So, it’s really a matter of printing the parts, painting, assembling, and putting everything together.

However, time is scarce, so this is one costume I haven’t started yet. The research is complete, but the execution is still pending.

Finally, how will you be celebrating May the Fourth this year?
I am currently working on new props and costumes. At some point probably a movie marathon to watch a whole bunch of films for the 100th time—especially the original trilogy, which I’ve seen even more than that.

To learn more about Vincent Rondia and his work visit www.makeitso.ooo, or connect with him directly by scanning the QR code below:

[All images courtesy of Vincent Rondia, unless otherwise stated]