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Abstract
Freeform optics have traversed the gap from theoretical to practical application propelled by ultra-precision multi-axis machining, like diamond turning and milling. Utilized for complex infrared sensors to human vision correction, freeform optics are a versatile technology, permeating industry. Manufacturing and application of dynamic freeform optics, where relative motion of these freeform surfaces can enable expanded and improved or new functionality of an optical system, is a next step. This work researches the manufacturing, metrology, and fixturing of dynamic freeform optics. The first part of this dissertation concentrates on evaluating manufacturing paths for glass dynamic freeform optics. Leveraging an iterative design process and metrology techniques, a method for production of high-quality optics is developed. Methods explored are direct glass diamond milling and precision glass molding. Metrology evaluations led to development of a six degree of freedom surface analysis that utilizes simulated annealing for optimization. Major results from the precision glass molding indicate high-volume production of transmissive glass freeform optics is possible. The second part of this dissertation details research in the manufacturing of two separate dynamic freeform optics and optomechanics. For prototyping of visibly transmissive dynamic freeforms, a shift was machined into the optical surfaces. These dynamic systems allow for novel light management and improved depth of field in high-magnification systems. Also detailed is the manufacture of a non-dynamic freeform illumination optic. All of these processes clarify methods for future manufacturing of freeform optics and optomechanics. Each of these optics illustrate how process chain development and cost-effective production is required for long-term success.