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Published 17:23 18 Dec 2015 GMT
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The actor, 69, who reprises his role as the droid in the latest instalment, had been wearing the costume for 40 years.
Rather than offering up a new famous gold bodysuit, he had to ask for it.
He said: "It's unconformable in all the places that when it is uncomfortable, it's very uncomfortable. When JJ asked me to be in the costume I said yes, but can we get a new one? After 40 years I think we have to change. It was beginning to smell pretty bad. And they 3D printed it."
Director J. J. Abrams gave Anthony the option of just providing the voice for the character, but the actor insists he would never have taken the easy route.
He explained to Alan Carr on his show Chatty Man: "I had a call from the producer who said, "Would it be alright if JJ Abrams called me?" What did I say? I said yes. Then he called and asked if I would be in the movie and I said yes. He asked if I would like to be just the voice and I said no and he said, "Quite right". It always is me in the suit."
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