Hi, I’m Robert Rodgers, the creator of Wicked Armor

Thank you for visiting Wicked Armor and taking an interest in my work. I have been creating costumes and props for the past 11 years, meticulously perfecting my techniques, and I am grateful to everyone who has supported me on my journey. Thank you!


Personal Inquires: wickedarmor.com/contact


Facebook: facebook.com/wickedarmor
Twitter: twitter.com/wickedarmor

About Me

My creative interests are varied, but costuming and replicas are a primary passion. I can rarely watch a film or play a videogame without finding new inspirations, and I want to make them exist in the real world. I have an absolute passion for solving technical, artistic problems, and there are always new technical challenges in sculpture and costuming.

I started making costumes as a teenager with help from mom and began selling my work frequently around 2004 from my college apartment. I turned my hobby into full-time work around 2006 and expanded to a home-based studio in 2008. I built a studio and shops in my backyard where I work today.

In school, I majored in Fine Art and then Physics, and I have a family with Melanie, Liam, and Ella (our Pomeranian)… and Koopa (our giant tortoise), and lots of koi fish and other animals.
Hobbies: anything creative, exploring nature, canoeing, creative writing, physics, programming, drawing, piano, home improvement projects, videogames, reading.

I am grateful to everyone who has supported my work and passion over the years. Thank you

The Workshop

Sculpture work and mold-making require a lot of space. I used to monopolize my college apartment living rooms, but I bought a house in 2008 with a horse barn that I could use for messy work and have expanded and improved my workspace a lot since then.

Shortly before my son was born, I built a new work area with AC and moved my work out of my house. I have always been interested in movie set and theme park design, so I took the opportunity to experiment with stucco and water feature construction in the backyard. Once I felt comfortable with the materials, I stuccoed my entire house to look like a refurbished Mediterranean ruin.

The more parts and molds I make, the more space it consumes, so building and construction is part of the job. Fortunately, now I have separate areas for creation, hand paint, assembly, spray paint, tool work, storage, and a shipping office. It is nice to spread out and organize things.



Brian Muir

Sculptor of the original Vader helmet based on one small sketch by John Mollo and the Vader body armor based on McQuarrie’s concepts. It meant a lot to me to meet him and hear about his experiences and techniques.

Drew Karpyshyn

Drew introduced himself when I was taking a break in costume. He wrote most of Knights of the Old Republic video game story and dialogue, and also wrote for the Mass Effect video game series and several other novels.

Sam Witwer

Star of the Star Wars video game series The Force Unleashed and the popular television show Being Human, among other roles.

My son’s first Star Wars Celebration

He walked right up,  hugged R2D2 and then followed him around.

Cosplay With Melanie

Melanie was interested in cosplaying for DragonCon and chose to suit up as Cassandra from Soulcalibur IV. Making the costume took a while, but she looked great and had a blast.

Jay Laga’aia

I met him at his honorary 501st member induction party. He was Captain Typho in Star Wars Episodes II & III and loved my Sith Stalker costume.

Matt Wood at First DragonCon 2006

Sound designer at LucasFilm/Skywalker Sound and the voice of General Grievous and battle droids.
I made a Grievous costume for my first DragonCon and planned to enter the contest, but when I got to DragonCon, the line wrapped around the building. It took over an hour to get inside, and I had to run to the hall with my costume. The guy in charge said I was too late to enter, but I was determined. I saw a George Lucas look-alike who was working the event and asked if he could help. He said he’d handle it and took my paperwork up to the sound booth. In line for the stage, someone told me that Matt Wood, the voice of Grievous, was one of the judges, and the guy who first rejected me was also the announcer and seemed a bit surprised to see me walk on stage. The audience roared, and Matt Wood quickly grabbed up a mic and started doing Grievous’s voice. I won my category, and Matt slipped the medal over Grievous’s head at the ceremony. I hung out with Matt a few times after that, and he’s a great person, who has since been nominated for 3 Academy Awards.

Delta Squad at Celebration 2017

I had dreamed of putting together a Delta Squad since 2005 and did my first helmet sculpt around that time. I actually made my first set of RC armor minus backpack in 2006, but I was unhappy with it. I finally made it a goal to finish the armor and get the 4 Deltas complete in time for SWC2017. I actually painted them all and did some of the final assembly in just 3 days (with little sleep), but they were not quite finished (Scorch nearly was). Now I have molds for the accessories for all of the individual Delta (and Omega) squad members.

General Grievous at Almost Every  Con

My father-in-law wears this costume any chance he gets, which is pretty much whenever I have time to make one before an event, and it always draws amazing crowds. When everyone is ready to call it quits for the day, Mike keeps on going. I do make these on commission, and clients are usually surprised at the reasonable price.


You can see my full body of works on the Portfolio page. I do offer some pieces for commission so please contact me for details.



You can find the latest news and progress updates on my current projects using the link below.