To repair himself, Vader manipulated parts from Infil'a's droid Arex into usable parts to cover the gaps in his armor, successfully upgrading it to defeat the Jedi by endangering Al'doleem civilians.
And while the suit did keep him alive, it also hindered Vader's abilities and potential as a Force-user. But unknown to Palpatine, this decision would result in his demise. Darth Vader was still undoubtedly powerful, and the suit made him more intimidating than Anakin could ever be. But the suit also limited his power.
Darth Vader's suit was destroyed by Emperor Palpatine after Star Wars: Episode V - The Empire Strikes Back. Vader had to rebuild his suit with outdated droid parts that amounted to little more than junk.
In Legends, Vader had the chance to upgrade his suit. This suit would have allowed him to come closer. to his full potential, giving him the speed of Anakin Skywalker. but the strength of a droid. However, this procedure was risky.
by Palpatine to be stiff, uncomfortable, and downright as painful as possible for Vader. This served to do 2 things. One, it kept Vader in a constant state of pain, which fueled his anger and made him stronger, and 2 it served as a persistent reminder of his failure. and of his lost potential.
Kylo Ren's obsession with Vader is clear, but Star Wars never explained how he acquired the helmet. It is speculated that he may have found it himself on Endor, or it could have been passed down to him by Supreme Leader Snoke.
Vader's suit is unbearably itchy. He also has needles stuck in him all the time. The Dark Lord has claustrophobia due to his suit. The iconic "I am your father" line was initially kept secret, even from the actors.
Vader constantly experiences excruciating pain due to the suit's design. Though he once perceived it as one of the suit's major downfalls, he later came to embrace it as it fueled his rage, allowing him to strengthen his connection to the Dark Side.
Could Anakin Have Ever Been Defeated If Not For Mustafar? Anakin would have only grown more and more powerful if he wasn't held back by his suit, and this very likely would have been him an unbeatable force.
The apparatus of Vader's mask was designed to support his breathing. The armor's boots featured magnetic clamps, which could magnetically adhere the suit to a metallic surface, while the legs were heavily armored and able to withstand at least glancing blows from a lightsaber.
Granted that it had just been a year since their last match-up, but the body's deterioration can rapidly increase as someone gets older. Coupled with the fact that Anakin had long been reliant on his armor which means that in reality, he's in worse shape under his suit than he might appear in Return of the Jedi.
According to Lucas, Vader operated at twenty percent less strength than the Emperor. While this was still impressive, it also shows how much more powerful he could have been as Anakin. Had he emerged unscathed from his duel with Obi-Wan, conquering the galaxy would have happened much faster.
But while it was out of character for a traditional Sith Lord, Vader's past as Anakin Skywalker showed that his compassion towards the soldiers he led was a major part of his character.
If he hadn't been placed in his new armour and had been left on Mustafar by the Emperor who was disappointed with his failure to kill Obi-wan then he would have died. If he had won the battle then his force powers would only grow and it is estimated that he would be about twice as powerful as Palpatine.
Darth Vader weighed 120kg (264 lbs), and most of that weight is because of the armor's steel and obsidian components. This means Darth Vader is unable to move at all at speed, and he needs the assistance of cybernetics.
While Vader was being reconstructed and operated on, Palpatine made sure that he had no anesthetic. so that he would become stronger in the Dark Side. through his pain. However, Palpatine also secretly sabotaged Vader armor, giving him outdated technology.
Overall, Suitless Darth Vader would be very powerful and would likely out-scale most Sith from legends and canon but with him not being balanced in the force and lacking mental clarity (which he would lack both of) then he'd still fall short of being the most powerful Sith lord.
