High-performance freeform optical systems, designed for broad spectral imaging fromthe visible to the far infrared, place new demands on optical design, precision manufacturing,and precision metrology. In this dissertation, four key aspects are addressed(i) precision placement of freeform optics, (ii) closed loop iterative manufacturing andmetrology, (iii) advanced materials, and (iv) design for manufacture. The dissertationincludes a new kinematic mount design used for manufacturing and metrology of afreeform optic, an experimental study on additively manufactured silicon carbide foroptical applications, and a new design methodology for higher efficiency lightweightmirrors considering additive manufacturing as the main process chain.To meet the tolerances on figure, roughness, and relative positioning in such systemsrequires the ability to perform metrology and manufacturing corrections onfreeform optics in a continuous feedback loop. This feedback loop requires a commoninterface for machining and manufacturing platforms. Chapter 2 describes thedesign, analysis, and testing of such an interface suitable for use with single pointdiamond turning and deterministic micro-grinding. The interface utilizes a torsionallypreloaded, robust, kinematic mount capable of supporting manufacturing processloads while maintaining the position repeatability in five degrees of freedom requiredfor the measurement and correction of optical figure. Results from a prototype systemdemonstrate an absolute and relative in-plane position uncertainty less than 200nmand 50 nm, respectively, and the axial position uncertainty of 40nm absolute and10nm relative. The absolute and relative angular positioning uncertainties less than1 μrad and 0.25 μrad respectively. The results exceed the requirements for many opticalsystems. The mount is also suitable for use in opto-mechanical assembly so thatthe same platform can be used for manufacturing, metrology, final assembly, testing,and service.Many of the properties of silicon carbide (SiC) are advantageous for optical applications,such as telescope mirrors and industrial laser systems. However, the base shapesof complex components are costly and difficult to manufacture. Leveraging additivemanufacturing, near net complex components are readily processed. In Chapter 3, aninvestigation on the post processing of additively manufactured SiC (AM SiC) comparedto chemical vapor deposited (CVD) SiC. The specific grinding energy for theAM SiC was lower than CVD, however the trends were the same. A specular finishwas observed on both materials but the AM SiC finish was limited due to residualporosity.Additive manufacturing is a disruptive technology that can be leveraged by theredesign of components in most engineering fields. The fundamental engineering resourcesfor lightweight mirrors were developed more than 30 years ago with a maindesign limitation, state of the art manufacturing. Chapter 4 presents two designmethodologies for the design of lightweight mirrors. The first method utilizes analyticalexpressions to design a traditional isogrid mirror, which provided the foundationfor most lightweight mirrors to date. The second method employs a combinationof topology optimization, lattice infill, and analytical estimation to develop an advancedlightweight mirror designed for additive manufacturing. The advanced mirrordesign outperforms the traditional design for each functional requirement including a94% reduction in predicted surface quilting and a higher specific stiffness. The manufacturingof the advanced mirror is only possible with an additive manufacturingprocess.Chapter 5 provides a summary of the work along with the most recent findings andpotential future work.