A must read: John Scalzi’s Guide to the Most Epic Fails in Star Wars Design. A few of my favs:

R2-D2

Sure, he’s cute, but the flaws in his design are obvious the first time he approaches anything but the shallowest of stairs. Also: He has jets, a periscope, a taser and oil canisters to make enforcer droids fall about in slapsticky fashion — and no voice synthesizer. Imagine that design conversation: “Yes, we can afford slapstick oil and tasers, but we’ll never get a 30-cent voice chip past accounting. That’s just madness.”

. . .

Stormtrooper Uniforms

They stand out like a sore thumb in every environment but snow, the helmets restrict view (“I can’t see a thing in this helmet!” — Luke Skywalker), and the armor is penetrable by single shots from blasters. Add it all up and you have to wonder why stormtroopers don’t just walk around naked, save for blinders and flip-flops.

The commentary by indignant Star Wars fans is funny too . . .

[H/T Phil]