The Design Sensitivity Analysis and Optimization (DSO) tool, developed initially for sizing design application, has been extended to support shape design applications of structural components. The new capabilities including shape design parameterization, error analysis and mesh adaptation, design velocity field computation, shape design sensitivity analysis, and interactive design steps, are discussed. These capabilities are integrated on the top of the DSO framework that includes databases, user interface, foundation class and remote module. The DSO allows the design engineer to easily create geometric, design, and analysis models; define performance measures; perform design sensitivity analysis (DSA); and carry out a four-step interactive design process that includes visual display of design sensitivity, what-if study, trade-off analysis, and interactive design optimization. Additionally, a 3-D tracked vehicle clevis is presented in this paper to demonstrate the new capabilities.