“Adapting Zurg for our movie was a tall order,” says sets art director Greg Peltz. “The original design from Toy Story 2 is iconic, and we wanted to draw from that source material as much as possible. Lightyear also features Buzz’s antagonist, Zurg (pictured below), who is voiced by James Brolin. Most of the fabric is replaced by well-articulated hard surface pieces that afford both mobility and maximum protection,” Kalal said. “Buzz can perform demanding physical tasks outside his spaceship and this suit. The wrist communicator is strapped right onto the suit.”Ī more familiar look is a later Space Ranger suit - an EVA, or extravehicular activity suit. These were considerations throughout, including when the team designed Buzz’s first launch and entry suit, the XL 01, which “takes us back to the early days of human space exploration, with function over form. The chest box is bulky and secured with a webbed harness. And all those layers add structure and change the way a wearer can move.” They’re structured with layers upon layers of cooling wires, heavy metal rings, an impermeable outer shell, utility gauges and instruments. The purpose of a launch and entry spacesuit, Kalal explains, is “to keep a human alive in space or water long enough for a rescue operation.
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