Amorphous solid dispersions of poorly soluble drugs have been injection moulded in order to assess the effect of moulding conditions on drug release. Two pharmaceutically accepted polymers were used as matrices; a cellulose derivative, HPMCAS and Soluplus®, a graft copolymer of polyethylene glycol, polyvinyl caprolactam and polyvinyl acetate. Two model drugs were used in the studies, ibuprofen and felodipine, having low and high glass transition temperatures respectively. Solid dispersions of each drug-polymer combination were produced by twin screw extrusion prior to injection moulding into a twin cavity caplet mould. Drug release was found to be slower from moulded caplets compared to that of extruded pellet as a result of the densification of the moulding process. Release rate was found to depend upon the formulation and injection moulding process conditions. In particular, the stability of ibuprofen-HPMCAS was investigated after ibuprofen crystals were observed to form on the surface of the moulded specimens. This surface recrystallisation was found to depend on moulding and storage conditions. DSC, XRD, near infra-red spectroscopy and confocal microscopy were used to monitor crystal formation.