A costume's sole purpose is to be seen as part of a film or theater production - part of an overall work of art (entertainment).
A traffic light's purpose is to signal a driver to react (stop, go, yield).
Exactly. What you are describing is its utility. If the intention the designer of the object (be it helmet or traffic light) had while making it was to meet the need to fulfil that utilitarian purpose, it does not meet the legal requirements to be considered a work of sculpture.
I don't see how the rights can be separated.
If someone was selling copies of drawings from the original animated Snow White would that be legal in the UK?
The drawings pre exist the animated film, but they are part of it - the two are intrinsically linked. Since the film is an undisputed copyrighted piece of art I don't see how it can be legal to copy any part of it.
So essentially the UK courts are saying anyone is free to copy the Stormtrooper costume, but you may still not copy a Stormtrooper in another form (sculpture, drawing, etc) because that would fall under the film's copyright. That's idiotic.
Drawings and paintings are expressly included in the Act of Parliament in question as automatically attaching copyright. As is sculpture. The problem is sculpture is undefined in the Act and the court has to make its own definition based on the pre-existing case law. There is no question that the drawings are copyrighted material (subject to rules on perpetuity, but that is a whole other can of worms).
There is also nothing to say a prop can't be sculpture if the prerequisite intention to create art is there. The appellate judgment explicitly stated it should be looked at on a case by case basis. This is not a blanket judgment rendering all props outside copyright.
Because the likeness of the Stormtrooper armour, which is the difinitive form from which all later works are derived, is in the public domain now, you can exploit it any way you see fit. Drawings, paintings, sculptures, and yes replicas are all based on the original helmets, not the film which followed it. Any work made now based on the Stormtrooper design now holds exactly the same legal weight as the images in the films.
Of course this is only within the jurisdiction of the UK courts.