Abstract: Method of making a multilayer article including providing a first substrate and providing a second substrate. The method further includes disposing an expandable insulating material on an inner surface of at least one of the first substrate and the second substrate, wherein the expandable insulating material is in a first condition during disposing. The second substrate is adhered to the first substrate with the expandable insulating material therebetween to form a blank, wherein an insulating space is defined between the first substrate and the second substrate with the expandable insulating material therein and the insulating space includes a first volume. The method further includes forming the blank into the article and expanding the expandable insulating material to a second condition by application of energy, wherein the expandable insulating material in the second condition increases the insulating space to a second volume.