This paper explores the applications of feature-based representation and design in the area of design for manufacturing to incorporate the tooling and process considerations into the early stages of bonnet tool design. The goal of this research is apply the concepts of feature-based design and to development an interactive design tool using relations and arrive at optimal design for the given process conditions. This paper illustrates the development of a tool design aided system that was constructed using these concepts and applied to designing bonnet sheet metal parts.