For the armour no, I don't think AA used the original moulds (except maybe the shoulder bells).

Honestly AA will say anything and change as necessary to back his story, even the Judge pointed this out... AA's helmets if they originate from any part of the original mold, then the mold has be revised and rebuilt creating many distinct differences, making it a totally different beast in the end... He even revised his story about the molds several times as differences were pointed out, and to this date can't explain where the 'swoop' went on the back of the helmet...

Sorry to anyone that has or had a glimpse of hope, hold on to it if you must, but IMO there is NO way AA's parts originated from original molds... The only part that I have any hesitation towards would be the face plate, but even that hesitation is small as I believe it is more likely derived from a casting taken of one of his "prototype" helmets prior to him selling them off...

39. Mr Ainsworth made several prototypes as he tried to get to a satisfactory design. In his first witness statement he suggested that he gave a prototype to Mr Pemberton at the beginning of February, and the latter in turn showed it to Mr Lucas. However, having studied Mr Pemberton's diary closely, along with Mr Mollo's diary entries, Mr Ainsworth changed the chronology and participation of the parties significantly. Having originally portrayed the situation as one in which he did not know who the end user was, and in which he did not meet Mr Mollo until mid-February, he then suggested that he met Mr Mollo as early as 23rd January. He also materially shifted the date on which he said he was asked to create other helmets from March to this January date. Whether he was right about that, I think it likely that he did meet Mr Mollo before mid-February. They probably met in the last week of January, either at Mr Ainsworth's premises or at Mr Pemberton's, and that enabled them to have a discussion about the then form of the prototype helmet. There was discussion about further modifications to the design – Mr Mollo accepted, and indeed asserted, that there were changes which were discussed between him and Mr Ainsworth. There was an exchange of ideas, probably over the next week or two, leading to the presentation of what seems to have been a final prototype to Mr Lucas on 17th February. There was a dispute as to the date when the first prototype was handed over, but the precise date does not matter; it was at some point within the last 10 days of January 2006. There may have been a little discussion over the modification of detail. Mr Lucas, who was still exercising the close and detailed control that he had hitherto exercised, approved the helmet by 19th February and he and Mr Mollo said that they wanted 50 of them. They dealt with Mr Pemberton in relation to that. Mr Pemberton told Mr Ainsworth that he wanted 50 helmets and Mr Ainsworth quoted £20 per helmet. Mr Pemberton said he would have to get back to his customer about that and a couple of days later the price was approved. Mr Ainsworth set about making the 50 using his moulds and vacuum moulding machinery. Some were made in a khaki plastic and painted white, but that was less than satisfactory because the paint tended to come off, so he made most in white ABS. They were delivered to the studio during March and Mr Ainsworth invoiced Mr Pemberton for them. He was duly paid. More were produced later.

The Stormtrooper armour
40. The Stormtrooper armour is another detail conceived by Mr Lucas. Mr Muir told me how his conception was embodied, in its early stages. The armour was the first project he worked on in the film. He worked from the two McQuarrie drawings given to Mr Pemberton and Mr Ainsworth. A plaster cast of an average-sized actor was taken, and used as a sort of tailor's dummy on which armour was modelled using clay. During the modelling phase changes were made as required by those involved in design, which must have included Mr Lucas. The final sculpt was approved by both Mr Lucas and Mr Barry. That approval having been given, the model was broken down into sections and a rubber mould was taken (within a fibreglass case). From that rubber mould a plaster cast was made, giving the same shape as the original sculpture. Mr Muir then worked on the plaster by carving to produce a more refined version of the original clay shapes. Again, Mr Lucas was involved in approving detail at this phase of the operation. The detail was sharper so that when (as would happen later) moulds were produced, the detail would survive through the ensuing process into the final shapes. This phase, Mr Muir said, took him about 4-5 weeks and was finished by the end of January 2006.

I don't disagree with you...but I don't see how he revised the face to that extent given his limited knowledge of what is accurate and it still looks like the stop-that-ship and move along faces....

and certainly the judge shot down many of the claims from the US judgment.

Actually I don't believe the Judge shot down any of the claims of the US judgment, in fact he conceded that US copyright infringement was made... From the looks of the paperwork the trademark issues were never pressed in the UK nor the unfair competition issues, that are obviously US and California specific...

In all honestly the Judge left the door wide open for continued litigation, and I suspect nothing less but continued litigation...

Also AA lost his claim, meaning his chance of recovery is gone making paying for continued litigation extremely hard on him...