A reconfigurable tool and/or die geometry and methods of use generally comprise forming at least a portion of a shape defining surface with a shape memory material. In response to an activation signal, the shape memory material changes geometry of the shape defining surface to provide a means for forming parts with different geometries from the same tool and/or die. In an alternative embodiment, an insert for a tool and/or die can be used, wherein the insert has at least a portion of its shape defining surface formed of a shape memory material. Also disclosed are processes for forming a first part with a defined geometry and a second part with a defined geometry different from the first part defined geometry using a reconfigurable tool and/or die as well as a reconfigurable insert with a standard tool and/or die.