A method for manufacturing a machine component is provided. The method includes forming a machine component substrate wherein the substrate has a substrate surface region. The method further includes forming at least one primary thermal barrier layer including a first ceramic thermal barrier material having a first porosity. The method also includes forming at least one secondary thermal barrier layer formed over at least a portion of the plurality of primary thermal barrier layers. Also, the secondary thermal barrier layer further includes a second ceramic thermal barrier material having a second porosity that is greater than the first porosity. The method also includes forming at least one tertiary thermal barrier layer comprising a smooth coat material, wherein the tertiary thermal barrier layer is formed over at least a portion of the secondary thermal barrier layer. The secondary thermal barrier layer facilitates reducing a delamination of the tertiary thermal barrier layer.