John Boyega
Credit: Steve Zak Photography/WireImage

Defending the Empire is no easy task. But Stormtroopers face even bigger challenges than that—especially when it comes to running around in their temperature-controlled survival gear. In fact, wearing the costume is hard work in itself, according to Star Wars: The Force Awakens star John Boyega. He plays Finn, the lead First Order Stormtrooper in the much-anticipated movie, which hits theaters on Friday, Dec. 18. And Boyega recently told InStyle that he experienced quite a few wardrobe malfunctions while filming.

“My Stormtrooper suit would chip underneath the armpits and in between the thighs,” Boyega said while celebrating the launch of the Star Wars “Force4Fashion” initiative between Disney and Bloomingdale's in New York City. “So they had to do a lot of editing for my costume and shave some areas down.” But even before the smooth white armor was chiseled to perfection, donning the getup was no easy feat. “Originally, it took 45 minutes to put the costume on,” said Boyega. “But after a while, we got it down to about 10.” By the end of filming, Boyega didn't just save time—he also saved manpower. “What started as a four-man job turned into a one-man job,” he said. “So that was really good.”

John Boyega Star Wars
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With his costume successfully in place, Boyega embraced a teamwork mentality on the set. He offered glowing reviews for his co-stars Daisy Ridley and Lupita Nyong’o. "They're all great," said Boyega, but the actor remained skeptical of one cast-mate in particular: BB-8, the domed robotic droid. “BB-8 is the only one that I’m not too sure about," Boyega said. “So we’ll be in touch about that guy—but everyone else is fantastic.”

The cast has bonded while promoting a film of such intergalactic proportions. “We’re really a big family about to introduce this new movie to the world," said Boyega. "And I know that it’s going to be a hit.”