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To develop an intelligent process design system, a process knowledge modeling approach is proposed to help engineers determine the values of parameters. First, various models are introduced to represent different kinds of process information. Then, a binary tree-based approach is proposed for representing formula-based process knowledge, together with an ordered tree-based approach for representing table-based process knowledge. Thereafter, an aggregate model of process knowledge is established, which can effectively integrate process template with route selection knowledge, formula-based process knowledge, and table-based process knowledge. Finally, a knowledge-based prototype system for intelligent process design is developed. The process design of a complex cable product is taken as an example to verify the modeling method. The result demonstrates that the proposed approach can enhance the decision-making capability of an intelligent process design system, which can thus improve the efficiency and quality of process design.