Abstract: A method of manufacturing a structural unit includes the steps of: (a) engaging a carrier within at least a portion of a mold, the carrier in operative communication with a face having at least one design portion extending into or out of an inner cavity of the mold; (b) placing material into the inner cavity of the mold, such that at least a portion of at least one side of the inner cavity comprises the face; (c) at least one of compacting, consolidating and condensing the material, thereby forming the structural unit; and (d) removing the structural unit and the carrier from the mold.

Abstract: Disclosed is an insert apparatus for a mold for manufacturing structural units. The insert apparatus includes a carrier for operatively engaging a portion of the mold, and is in communication with a face or an object having an engagement design portion thereon. The face is in operative communication with the carrier, and the engagement design portion extends into or out of the cavity of the mold. Methods of manufacturing such a structural unit, methods of retrofitting an existing mold for manufacturing such a unit and novel and improved structural units are also disclosed.