This paper describes issues relating to the Knowledge Management (KM) of expert roll tool design, as part of an initiative to improve the design process for cold roll forming. The management of knowledge has been used to standardise design practices in working towards automation, to improve lead times and retain expert knowledge within a metal forming organisation. The paper utilises the first two years of a real and ongoing 4-year case study, to examine KM and Knowledge Elicitation (KE) initiatives and specific problems experienced during the management of expert knowledge.