A method of forming maintenance-free rolling door vacuum slats includes an elongate tubular member forming a cavity with a substantially uniform cross-sectional configuration along its length and forming first and second opposing ends conforming to the cross-sectional configuration. A first cap seals the first end. A second cap seals the second end, a vacuum being formed within the cavity. The first and second caps are joined to the elongate member to form a hermetic seals to render the slat airtight forming a permanent vacuum insulation barrier that requires no maintenance to restore the vacuum within the cavity.