Abstract: A process for forming crushable, “synthetic” rocks from waste gypsum involves collecting natural and synthetic gypsum waste in the form of flue gas desulfurization (“FGD”). The gypsum waste has a sludge-like consistency and is passed through an extruder where the moisture in the waste gypsum is drawn off and the waste is densified. The removal of moisture is accomplished under vacuum. The densified waste gypsum is extruded through a die to create three-dimensional shapes with preselected aspect ratios.