Yes actually it was molded...when is someone going to finish their helmet? I can't finish mine unfortunately... :lol
Well I mentioned before a little bit about where the helmet is supposed to have come from...so here's a bit more.
This particular helmet and mask casting was made at ILM in
1988, from very old molds, among the oldest, in the current LFL inventory. The molds themselves were reportedly taken from the screen-used Darth Vader helmet in 1977, and that is consistent with details seen on the screen helmet at that time. I hope to contact the person who made the molds at that time. Unlike what I had previously thought, the molds themselves were apparently made in the United Kingdom, and later sent to the USA. They were at one point temporarily housed at the Marin County Facility of ILM, at which time this pull was made. It is thought that the molds themselves were made during post-production of ANH(during pickups), but certainly before the promotional tour as there are signs of wear that the original helmet had that are consistent from the time during or after production, but not during the tour (from the time the suit went to Don Post Studios).
Incidentally, the so-called RPF ANH (or Darth Jones) Vader helmet, which has been known about for quite some time, is a younger (and fully finished) brother of the SL ANH as they both originated from the same mold.
Of course I should add that skepticism, criticism and questions are all welcome....as I know I've made my fair share lately as well. :confused