Ok...Time for a little discussion.
I went back and checked my research and it seems that there was some conflicting thoughts on whether or not a plastic dome was used on ESB for R2. As we already know they mainly used the 8 new bodies that Tony Dyson had made, along with a combination of alu-domes and composite ones that were vac-metalized. I've never seen evidence, or heard anyone say that they vac-metalized the alu-domes...FYI...In fact, the ESB era domes that I've had first hand experience with were bare aluminum, and noticeably different than the ANH ones.
So...That brings me to this...Here for your viewing pleasure I submit a piece of evidence that a vac-formed dome may have been used for R2.
Anyone that has worked with alu-domes knows that the corners and cuts are sharp and straight...Very crisp edges.
Anyone that has worked with composites knows that replicating those sharp corners is no problem for composites...Basically, if a corner is nice and sharp on the original, it will be nice and sharp on the composite copy...
AND...Anyone that has ever vac-formed anything knows that it is VERY hard to hold sharp edges when vac-forming something either over something, or into a recess. In fact, if you take a look at these pics from the link Cole posted above, you can see what I mean...
http://astromech.net/?q=gallery&g2_itemId=33894
and...
HPIM0723 - Astromech.net
If you look really closely at the droids in the above pics, you notice that the edges of the recessed panel areas are slightly rounded and generally "soft". And I think we all agree that Roberts mold is most likely the source of those clear domes...
BUT...Now I want you to look at this pic...
http://astromech.net/?q=gallery&g2_itemId=4093&g2_imageViewsIndex=1
Notice the same "soft", slightly rounded edges on the panels...Notice the spacing of the HP hole (it's identical to the spacing on the dome mold pics above)...That is simply NOT a composite or aluminum dome in those shots, as the panel edges would be much sharper on either one.
It is my contention that the R2 dome in that pic is in fact a vac-metalized, vac-formed dome...With panels that are either plastic (or possibly alu) that were painted and placed in the recessed areas...In fact, the color and finish of the blue in this shot looks VERY much like the Dykem that has been recently discussed as the blue formula from ANH. I think the only difference is that this is Dykem over vac-metalized plastic, instead of Dykem over bare aluminum.
So...I see several possible scenarios for the mold that Robert has posted pics of to start this thread.
1. It is a mold made solely to be used for vac-forming the R3 clear domes
2. It is a composite pull for R2 domes that was re-worked into a vac-form plug.
3. It is the mold that was used for both clear R3 domes, as well as at least one (or more) vac-formed plastic domes.
Again...I've been studying the history of R2 and all his various incarnations for years. And new info is always popping up, so I'm not stating anything with absolute certainty. But I think the evidence shows that it's worth further discussion.
Jason