Demoulding, or ejection, is a critical stage of replication processes. It can be a particular problem for smaller parts which are weaker, and thus more prone to damage, during ejection from the mould. This paper describes a series of replication trials of flat plate and cup-shape geometries with tools of different surface roughness. More specifically it describes the design of a series of tool inserts and the measurement of the force needed to demould replicated parts under a range of controlled processing conditions. The actual force needed to demould parts from specific tool inserts of specific surface texture and geometry has been quantified through these experiments. This work is part of a larger project ongoing at Dublin Institute of Technology to develop an increased understanding of demoulding and how to quantify the force needed to actually demould such parts.