"I felt there was a void in women's cosplay armor that characterized the female form while giving a sense of power when wearing it," Weir, 40, tells PEOPLE. "I wanted to design a look which covered the body and was pleasing to look at. The armor also needed to appear it served a purpose."
It took the Los Angeles native – who sells his creations on his website Imperial Surplus – about seven weeks of designing, collaborating with friends, and getting input from the women in his life, including his wife Brooke, to complete the project.
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"I wanted to bring that all together, and have something that was smooth and organic-looking with intertwined hard geometric shapes," he says. "Most of all, I wanted something that could appear likely to fit into the Star Wars universe."
A highlight for the Memphis College of Art graduate was debuting his armor on women from the Star Wars costuming club 501st Legion at the Long Beach Comic Expo last month.
"It was a bit surreal for me to finally see an idea in my head take shape," he says. "Seeing them walking around and being asked for pictures was a wonderful feeling and a great accomplishment. I am so grateful I can share and use my talents and passion for the art I create to help bring people together in their love for Star Wars and costuming."