Process for forming a multilayer, multidensity composite insulator

A process for forming a multilayer composite insulator, comprising:

• forming an insulator precursor by orienting an insulation insert in a desired location (a) between a first facing layer and a first layer of a polymer based blanket material having a first softening temperature C or (b) between said first layer of a polymer based blanket material and a second layer of a polymer based blanket material having a second softening temperature D where C<D;
• applying heat to two opposing sides of said insulator precursor so as to soften said first layer of polymer based blanket material without softening said second layer of polymer based blanket material;
• applying pressure to said insulator precursor whereby said applied heat and said applied pressure mold said insulator precursor to a desired shape while also simultaneously providing a first zone having a first density A in said first layer of said polymer based blanket material and a second zone having a second density B in said second layer of said polymer based blanket material where A>B;
• and
• cooling said molded precursor to set said insulator in the desired shape.