Star Wars: 10 Things You Didn't Know About Darth Vader's Suit
7. His Mask Originally Had A Different Purpose
The script for the original Star Wars movie went through several changes over many years, and Vader was the subject of more than a few of these changes.
An early draft described him as a "tall, grim-looking general", before a later revision upgraded him to the destructive Sith Lord we're all familiar with today. Plus, the character's famous mask was initially meant to be an optional feature that he would sport on certain occasions, and not a permanent one that he needed to stay alive.
An early draft of the script had Vader crossing between two ships in space, so Ralph McQuarrie, who worked on the original trilogy, only created the mask to be used as a breathing apparatus in this situation.
But by the fourth draft, George Lucas had written in more of Vader's backstory, including the notion of the character needing a suit and mask after being badly burnt. From here, Vader was changed significantly, and was written and designed with the suit and mask being integral parts of his persona.