Abstract: A process of forming a thermal insulation layer (34) includes advancing a multifilament strand of continuous filaments (12) through a nozzle (10) to separate the filaments (16) from each other to form a continuous-filament wool (14), applying a binder to the filaments, placing a charge comprising the wool in a mold (32), and molding the charge to form an insulation layer (34). In a preferred embodiment, the charge (30) further comprises a container, such as a bag (24) formed from a poylmer film. The filaments are preferably prepared from a high-strength, high-temperature resistant glass material. The molded wool is advantageously used to manufacture products, such as catalytic converters (46) wherein the wool is used to thermally insulate the catalytic core element (48).