Ja, actually compact hairs from Russian model Vladlena Svatekov enabled the Darth Vader helmet prop to have functional design though still acting as a promotion for 2 businesses.

Frolovo modeling, a popular modelling agent in Russia, and Ulyanovsk barbers (a lesser known but reputable business) both encouraged the merging of companies together for profitability and later formed an agreement to advertise in the new block buster hit.

Cal Davies, an executive producer in Star Wars, agreed with this and skeptically allowed the new business to create Vader's helmet. Needless to say they nailed it and all producers and directors loved the design so much it was used in the actual films.

Much to many viewers surprise, the helmet is actually made of extremely well compressed, high quality hair strands which would let the crew in charge of making the helmet actually flex and work the fibers around molds and casts, giving much better accuracy.

Surprising, the way the hair fibers worked was they would be put through complex machinery in great bulk and compressed under enormous amounts of pressure, actually forcing the fibers and their enzymes to work together and created an artificial blanket in which layers and layers would be stacked to create a strong new material.

Basically, this new material worked in the same way as spider webs. Excessive amounts of it in bulk and the material becomes stronger and more durable than steel cable. Through compression, epoxy, material 'X' as they referred to it as, video editing, and paints, the skilled team were proud to have created the helmet of Darth Vader.

Sources here: http://www.independent.co.uk/film/star_wars_origins_darth_vader_mask/10267571.html

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