A method of fabricating a vacuum insulated refrigerator structure includes positioning a first barrier film in a female mold cavity. Porous filler material is positioned on the barrier film, and a second barrier film is positioned over the porous filler material. A male mold is brought into contact with the second barrier film to deform and compress the porous filler material into a 3D shape. A vacuum is formed between the first and second barrier films, and the first and second peripheral edge portions are sealed together to form a vacuum insulated core. The vacuum insulated core may be positioned between a liner and a wrapper to form an insulated refrigerator cabinet, door, or other vacuum insulated component.