[RamenRider]

Last time I read a novel it was the abruptness of the situation and sloppy work of the medical droids that made the suit what it is. Which is understandable I guess, it’s not like they had a perfectly fitting survival apparatus just lying around, probably started making something as soon as the Emperor took off with the injured Vader from Mustafar.

And the suit-up scene from the Kenobi series also shows connection ports all over his body, so it's not just a suit but also implants within his body to make it all come together. A system like that seems hard to improve, it's not like you can just safely cut open your body again and do it all from scratch. Maybe a miracle that the suit actually works in the first place.

Yeah yeah, it's Star Wars, science-fiction and all; surely they can find a better way. But this is also Star Wars, in a sense that it is weirdly realistic at times, and that kind of makes it unique. For Vader my idea is basically that they had to create a suit for him to survive in from scratch within hours, and after it was done it was done. Like Frankenstein’s monster, he's stuck the way it is now, as the primary goal was to make it work. They had a dying person to work with after all, time was of the essence.

And less than the Emperor forcing him to stay this way, another aspect is probably Vader guilt-tripping himself. He got into this mess, and is too proud to make it a more comfortable one. He would rather "master" the situation instead of feeling that he’s weak for making the suit better.