Dave Elsey on Star Wars Episode III FX

"We're also recreating a lot of characters from the earlier movies, such as the Emperor and of course, we show how Anakin Skywalker becomes Darth Vader," says Elsey.

Transforming a handsome actor like Hayden Christensen into a gruesomely tragic Darth Vader isn't easy, and Elsey had his hands full trying to create a ravaged Sith Lord fans have only seen glimpses of sans-helmet.

"At the end of Return of the Jedi, when his helmet comes off and we see what he looks like, we've had to kind of do the earlier version of that and we've had to really research that," Elsey explains.

"The difficult part with the Wookiees, is that they have a much bigger role in this movie than they've ever had before," Elsey explains. "We've basically body-casted every single actor who is playing a Wookiee; which means not only full body-cast, but full head-cast, hand-cast and feet-casts. Then we've had to produce fiberglass versions of those so that we can build up the muscle structure, and then build all the hair suits and everything that sort of goes on top of that as well as the mechanical heads. That's been quite difficult because I don't think anybody's ever attempted to do this many mechanical masks on screen before. This is quite a big thing."

Source: Official Site