I did print both masks. That's the Emperor's most trusted general with his very capable Storm Trooper (my assistant Holly). She loves cosplay and had the light saber, so the rest just fell in place. Here's a close up of the masks.
They are both based on this mask with a molded silicon seal. The Vader was a simple addition while the storm trooper was a lesson in Meshmixer and Fusion 360 together. I also printed face shields and straight versions of the mask for actual use. You can't believe how uncomfortable N95 masks are unless you have seen pictures of nurses after their shift.
Cool work on the masks! You're right about the N95s, had to wear one years ago while working in an underground communications vault, hated every minute of it.