Lightweight thermal shield

A method of manufacturing a lightweight heat shield (902) including obtaining a mold (950) having a molded support screen (960) with a molding surface configured to allow passage of air and moisture therethrough, and with the mold (950) adapted to generate a vacuum (972) from behind the support screen (960). The method also includes applying a wet insulation material onto the molding surface of the support screen (960) and generating a vacuum (972) to draw the moisture through the support screen (960) and consolidate a layer of insulation material (93) onto the molding surface. The method further includes removing the consolidated layer of insulation material (933) from the molding surface, installing the consolidated layer of insulation material (933) into an outer cover layer (920), and drying the consolidated layer of insulation material (933) within the outer cover layer (920) to form a light core insulation layer (930). (Automatic translation with Google Translate, no legal value)