These look like the same kind of thing, for $80 US:
nextag.com/deluxe-stormtroop … earch-html
They’re made with molded foam, which I guess is the next step on from what I was suggesting (shaped foam). In terms of matching the movies the armour is okay, but not great. Would be fine for a bunch of cannon fodder.
For US $899:
buystarwarscostumes.com/auth … stume.html
For £995 (armour) + £295 (helmet), from the guy who claims to have made the originals:
sdsprops.com/battlestunt-intro.htm (helmet)
sdsprops.com/armour-intro.html (armour, but not shoes)