Kylo Ren is certainly known for his distinct all-black costume that pays tribute to Darth Vader. However, Anakin Skywalker's grandson almost had a completely different look while Star Wars: The Force Awakens was still being developed. There were several looks that were considered before Lucasfilm settled on the mask that resembles the one worn by Vader. One of the Kylo Ren concept art even has an obvious connection to a character from Star Wars Rebels.
In the early days of Star Wars: The Force Awakens, Kylo Ren was referred to as 'Jedi Killer' because of his role in killing several of Luke Skywalker's apprentices. Not surprisingly, it was a name that had to have a look that would match the character's bloodlust. Because of this, concept artist Christian Alzmann came up with several terrifying designs for Kylo. Interestingly, Alzmann shared one of the designs he worked on social media.
Christian Alzmann posted the Kylo Ren concept art on his official Instagram account, and it depicts the character with grey skin, seemingly blind eyes, and a mask that covers the lower part of his face. It's a terrifying design that could have turned Kylo into a truly imposing figure that could scare his enemies into submission. You can see the image here.
It is unclear why Lucasfilm decided not to go with the design, but Christian Alzmann is glad to report that the concept art did not go to waste. The look was later used for the Fifth Brother, a character that would appear in the animated series Star Wars Rebels. However, the mask was removed to display the Inquisitor's face.
It might have been a better idea to use the Kylo Ren design for the Fifth Brother. After all, the Fifth Brother proved to be a scary character because of his connection to the Galactic Empire and his great use of the Force. Unfortunately, the Fifth Brother was still no match for other powerful characters. The former Darth Maul ultimately killed him in Star Wars Rebels.
This isn't the first time that Kylo Ren concept art was reused for a different character. Kylo was also imagined to have a shiny Stormtrooper armor, as designed by Michael Kaplan. However, the design was turned down by The Force Awakens director J.J. Abrams and was later chosen by Lucasfilm president Kathleen Kennedy to be used for Captain Phasma. Kylo was then given the all-black ensemble so he would resemble Darth Vader.
Kylo Ren returns in Star Wars: The Rise of Skywalker, which premieres on December 20.