A process for forming a multilayer composite insulator (10) includes: (a) forming an insulator precursor (24) by orienting an insulation insert (16) in a desired location between a first facing layer (12) of and a layer of a polymer based blanket material (14); (b) closing the insulator precursor in a molding press (26); (c) heating the insulator precursor in the molding press to a temperature sufficiently high to soften polymer binding fiber in the polymer based blanket material and cause reshaping; and (d) cooling the insulator precursor in the molding press so as to set the insulator precursor in its molded shape and complete formation of the insulator. Other relates processes are also disclosed.
