Dynamic block press, and associated methods and systems

A method for manufacturing a masonry block, comprising:

• premixing constituents to produce a pre-moistened compressible masonry formula having a moisture content of less than or equal to 12 percent in a first mixer;
• transporting the pre-moistened compressible masonry formula from the first mixer to a second mixer, the second mixer including:
• a mixing chamber extending from an upper end to a lower end, wherein the mixing chamber includes an inlet at the upper end and an outlet at the lower end;
• a mixer shaft extending downward from a first end to a second end;
• one or more tools attached to the shaft between the first end and the second end;
• and
• a rotation mechanism coupled to the first end of the mixer shaft;
• receiving the pre-moistened compressible masonry formula through the inlet, while the mixer shaft and the attached tools are rotating with a rotation speed equal to or greater than 1,000 revolutions per minute (rpm);
• processing the pre-moistened compressible masonry formula with the attached tools by mixing the constituents and breaking down aggregates and agglomerates in the pre-moistened compressible masonry formula, to produce a de-agglomerated product formula as the pre-moistened compressible masonry formula falls downward from the upper end and exits the outlet of the mixing chamber through the lower end, wherein the de-agglomerated product formula is subsequently compressible;
• receiving the de-agglomerated product formula at a block press that includes:
• a charge hopper;
• and
• a plurality of mold elements, wherein the plurality of mold elements include:
• a lower impact plate,
• an upper impact plate, and
• a plurality of side plates;
• wherein the de-agglomerated product formula is received in the charge hopper, and wherein the charge hopper controllably loads a predetermined amount of the de-agglomerated product formula;
• moving one or more of the mold elements to dynamically form a block mold for receiving the predetermined amount of the de-agglomerated product formula;
• with the charge hopper, filling the formed block mold with the predetermined amount of the de-agglomerated product formula;
• compressing the de-agglomerated product formula within the dynamically formed block mold to form a masonry block;
• controllably moving one or more of the mold elements to release internal pressure of the formed masonry block across one or more dimensions;
• and
• controllably moving one or more of the mold elements to remove the formed masonry block from the block mold.