Carbon Fiber Stormtroopers: San Diego Composites Engineers Build Star Wars‑Inspired Composite Armor

We showcased one of the helmets on the TV show "Pawn Stars," and it is now available for purchase in our online store.

Halloween arrived early this year for the team who call themselves the "Carbon Fiber Stormtroopers."

Leonard Carson, an engineering technician at San Diego Composites, had long dreamed of a carbon‑fiber Stormtrooper. He convinced three colleagues to transform the concept into a tangible prototype. Their shared passion for Star Wars and extensive experience with composites made the collaboration almost inevitable.

The project’s biggest challenge was cost. Carbon fiber is a premium material, and the team had to select the most efficient tooling, finishing, and manufacturing processes. They sourced only Grade A components from a local supplier and received additional resources from their employer, San Diego Composites.

San Diego Composites’ president championed the idea, even proposing a display in the company lobby. After reviewing the time, labor, and material investments, he performed a detailed cost analysis that covered tooling and the four complete suits. While the exact figure remains confidential, the project proved financially viable.

Browse below to see the final result. The team had a blast showcasing their craftsmanship!

Left to Right: Jon Blackler, Kevin Proum, Len Carson, Daniel Avina