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Lynx is a concept under study for prioritization in the 2020 Astrophysics Decadal Survey. Providing orders of magnitude increase in sensitivity over Chandra, Lynx will examine the first black holes and their galaxies, map the large-scale structure and galactic halos, and shed new light on the environments of young stars and their planetary systems. In order to meet the Lynx science goals, the telescope consists of a high-angular resolution optical assembly complemented by an instrument suite that may include a High Definition X-ray Imager, X-ray Microcalorimeter and an X-ray Grating Spectrometer. The telescope is integrated onto the spacecraft to form a comprehensive observatory concept. Progress on the formulation of the Lynx telescope and observatory configuration is reported in this paper.

The JWST Optical Telescope Element (OTE) assembly is the largest optically stable infrared-optimized telescope currently being manufactured and assembled, and is scheduled for launch in 2018. The JWST OTE, including the 18 segment primary mirror, secondary mirror, and the Aft Optics Subsystem (AOS) are designed to be passively cooled and operate near 45K. These optical elements are supported by a complex composite backplane structure. As a part of the structural distortion model validation efforts, a series of tests are planned during the cryogenic vacuum test of the fully integrated flight hardware at NASA JSC Chamber A. The successful ends to the thermal-distortion phases are heavily dependent on the accurate temperature knowledge of the OTE structural members. However, the current temperature sensor allocations during the cryo-vac test may not have sufficient fidelity to provide accurate knowledge of the temperature distributions within the composite structure. A method based on an inverse distance relationship among the sensors and thermal model nodes was developed to improve the thermal data provided for the nanometer scale WaveFront Error (WFE) predictions. The Linear Distance Weighted Interpolation (LDWI) method was developed to augment the thermal model predictions based on the sparse sensor information. This paper will encompass the development of the LDWI method using the test data from the earlier pathfinder cryo-vac tests, and the results of the notional and as tested WFE predictions from the structural finite element model cases to characterize the accuracies of this LDWI method.

The Advanced Technology Large-Aperture Space Telescope (ATLAST) is a concept for a 9.2 m aperture space-borne observatory operating across the UV/Optical/NIR spectra. The primary mirror for ATLAST is a segmented architecture with pico-meter class wavefront stability. Due to its extraordinarily low coefficient of thermal expansion, a leading candidate for the primary mirror substrate is Corning’s ULE® titania-silicate glass. The ATLAST ULE® mirror substrates will be maintained at ‘room temperature’ during on orbit flight operations minimizing the need for compensation of mirror deformation between the manufacturing temperature and the operational temperatures. This approach requires active thermal management to maintain operational temperature while on orbit. Furthermore, the active thermal control must be sufficiently stable to prevent time-varying thermally induced distortions in the mirror substrates. This paper describes a conceptual thermal management system for the ATLAST 9.2 m segmented mirror architecture that maintains the wavefront stability to less than 10 pico-meters/10 minutes RMS. Thermal and finite element models, analytical techniques, accuracies involved in solving the mirror figure errors, and early findings from the thermal and thermal-distortion analyses are presented.

Analysis of impacts on fused silica was motivated by the design of the mirror for the James Webb Space Telescope (JWST). The JWST is expected to have a large-diameter mirror shaded from sunlight but open to space. One of the candidate mirror materials is fused silica; the other candidate materials are ultra-low expansion (ULE) glass and O-30 beryllium. Historically, most meteoroid tests have concerned themselves with the degraded strength of the substrate; JWST is primarily concerned with maintaining its precise optical figure. Micrometeoroids can have velocities of 50 km/s or higher. Although the velocity in the analysis did not exceed 10 km/s, the computer model included a fit to shock Hugoniot data for fused silica with pressures as high as 700 GPa, typical of impacts at velocities higher than 10 km/s. The computer model also included the first-order phase transformation observed in fused silica. The calculations were made with the AUTODYN hydrocode [1], which includes smooth particle hydrodynamic (SPH) and Lagrange solvers with other modules and features for coupling them together. For the analysis of impact, both SPH and Lagrange methods were used. Using the static relaxation option, the analysis continued from crater formation to a late-time static solution from which the effect of the impact on the optics could be determined. Both low and high energy impacts were computed using the fused silica model. For the low energy impact, the computed crater depth, crater diameter, and spall diameter closely matched both historical data for fused silica and values measured by Auburn University/ Hypervelocity Impact Facility (AU/HIF) for two typical fused silica sites and one ULE site. For the high energy impact, the computed values matched historical data for fused silica but not the data measured by AU/HIF for three typical ULE sites. The discrepancy can be explained by the difference in the response of fused silica and ULE under impact, as seen in historical trends and as observed by AU/HIF. Optical interferometry of the surfaces of one of the mirrors revealed deformation in the vicinity of particle impacts that matched that estimated with a static model, and the deformation was consistent with that computed by AUTODYN.

2014 marks the crystal (15 th ) anniversary of the launch of the Chandra X-ray Observatory, which began its existence as the Advanced X-ray Astrophysics Facility (AXAF). This paper offers some of the major lessons learned by some of the key members of the Chandra Telescope team. We offer some of the lessons gleaned from our experiences developing, designing, building and testing the telescope and its subsystems, with 15 years of hindsight. Among the topics to be discussed are the early developmental tests, known as VETA-I and VETA-II, requirements derivation, the impact of late requirements and reflection on the conservatism in the design process.

The JWST observatory, scheduled for launch in 2018, has a large optical telescope passively cooled to below 50K. Due to the size of its large sunshield in relation to existing test facilities, JWST cannot be optically or thermally tested as an observatory system at flight temperatures. As a result, the telescope portion along with its instrument complement will be tested as a single unit very late in the program, and on the program schedule critical path. To mitigate schedule risks, a set of cryogenic tests with non-flight and flight-spare hardware will be performed earlier. These tests will demonstrate the optical testing capabilities of the facility, characterize telescope thermal performance, and allow project personnel to learn valuable testing lessons to reduce program risks. This paper describes a risk reduction thermal analysis of the “Pathfinder” cryogenic test program, focusing on the first test in the series. The process of developing the independent thermal analysis model for the JWST ‘pathfinder’ program is described, as well as analysis model guidelines developed specifically for the JWST program. The thermal math model consists of the “Pathfinder” telescope structure, two flight-spare primary mirror assemblies, a flight-spare secondary mirror, and a 20K cryogenic chamber shroud simulation. The rigorous model validation process is discussed, as is the thermal analysis performed to verify that test requirements could be met. Results of this analysis include thermal stability for multiple optical measurements, cooldown time to cryogenic temperatures enhanced by gaseous-helium free-molecular heat transfer, and sensitivity studies of shroud emissivity, shroud temperature profile, and properties of the cooling gas.

The James Webb Space Telescope (JWST) is an on axis three mirror anastigmat telescope with a primary mirror, a secondary mirror, and a tertiary mirror. The JWST mirrors are constructed from lightweight beryllium substrates and the primary mirror consists of 18 hexagonal mirror segments each approximately 1.5 meters point to point. Ball Aerospace and Technologies Corporation leads the mirror manufacturing team and the team utilizes facilities at six locations across the United States. The fabrication process for each individual mirror assembly takes approximately six years due to limitations dealing with the number of segments and manufacturing & test facilities. The primary mirror Engineering Development Unit (EDU) recently completed the manufacturing process with the final cryogenic performance test of the mirror segment assembly. The 18 flight primary mirrors segments, the secondary mirror, and the tertiary mirror are all advanced in the mirror production process with many segments through the final polishing process, coating process, final assembly, vibration testing, and final acceptance testing. Presented here is a status of the progress through the manufacturing process for all of the flight mirrors.

During 2009, Tinsley finished most of the Configuration 1 pre-cryo test Computer Controlled Optical Surfacing (CCOS) operations on the James Webb Space Telescope primary mirror segments and in mid-2009 we began the Configuration 2 post-cryo test CCOS operations. After completing the grinding and polishing operations, including final figuring to a cryo-null target, we delivered the finished Engineering Development Unit (EDU) to Ball Aerospace Technology Corporation on 4 December 2009. Achieving fabrication and metrology conditions to meet the specifications for this off-axis ~1.5 m hexagonal point-to-point segmented mirror required special methods. Achieving repeatable and accurate interferometric alignment of the off-axis aspherical mirror surface and stable thermal gradient control of the beryllium substructure during tests required rigorous component and system-level validation. Final optical wavefront measurements over the various spatial frequency ranges have demonstrated that all of the requirements are met. This success has validated our processes of fabrication and metrology and allows us to proceed with the production of the 18 flight mirror segments. The first finished flight mirror, the Tertiary Mirror, was shipped to BATC on 24 February, 2010. Performance of that mirror is reported here also.

Nested flat plates bent into the Kirkpatrick-Baez parabolic geometry and supported at discrete points are one means of obtaining large area grazing incidence x-ray optics with good angular resolution. A method for optimizing the on-axis resolution combining finite element and ray trace techniques with selective masking is presented. The optimally determined supported point location technique can lead to greatly reduced in situ labor costs.

The context, preparation, and facilitization of Tinsley to produce the 18 JWST primary mirror segments are described, and an overview of the Project at Tinsley is presented. The mirror segments are aggressively lightweighted, approximately hexagonal, and approximately 1.32m flat-to-flat. While the optical finishing approach is strongly seated in Tinsley's Computer Controlled Optical Surfacing (CCOSTM) technology, extensions have been implemented to address safe and efficient nearly simultaneous flow of the high value mirror segments through numerous cycles of optical finishing, processing and metrology steps. JWST will operate at cryogenic temperatures, and Tinsley will do final figuring from a "hit map" made during cryogenic testing at the NASA MSFC X-Ray Calibration Facility (XRCF). A formal beryllium safety protocol has been established throughout. Extensive handling fixtures assure that the mirrors are moved from station to station experiencing low accelerations. A rigorous qualification process is applied to each new fixture, machine and instrument. Special problems of cryo figuring, and co-finishing the segments to stringent specifications are described.© (2006) COPYRIGHT SPIE--The International Society for Optical Engineering. Downloading of the abstract is permitted for personal use only.

An overview of the JWST mirror segment fabrication at Tinsley will be presented. The 18 JWST primary mirror segments are lightweighted 1.3m flat-to-flat Beryllium hexagonal substrates.

The mirrors flown in the Chandra Observatory are, without doubt, some of the most exquisite optics ever flown on a space mission. Their angular resolution is matched by no other X-ray observatory, existing or planned. The promise of that performance, along with a goal of achieving 1% calibration of the optics' characteristics, led to a decision early in the construction and assembly phase of the mission to develop an accurate and detailed model of the optics and their support structure. This model has served in both engineering and scientific capacities; as a cross-check of the design and a predictor of scientific performance; as a driver of the ground calibration effort; and as a diagnostic of the as-built performance. Finally, it serves, directly and indirectly, as the primary vehicle with which Chandra observers interpret the contribution of the optics' characteristics to their data. We present the underlying concepts in the model, as well the mechanical, engineering and metrology inputs. We discuss its use during ground calibration and as a characterization of on-orbit performance. Finally, we present measures of the model's accuracy, where further improvements may be made, and its applicability to other missions.

We present new results from a program to develop large area X-ray telescopes that are made from thin plastic shells. We use multi-shell cylindrical lenses in a point-to-point configuration to form full aperture images of the small focal spot in a an X-ray tube on a microchannel plate detector. The image data are analyzed to yield radial profiles and encircled energy curves. The derived parameters can be extrapolated to the case of a telescope that is a conical approximation to Wolter 1 optics. The plastic shells can be coated with suitable mono- or multilayers that allow for a wideband coverage of X-ray energies. Our current program is focused on the development of a large area, hard X-ray telescope for a balloon payload (see the paper 4851 -107 by E. Silver, et al at this conference).

We present results from a program to develop an X-ray telescope made from thin plastic shells. Our initial results have been obtained from multi-shell cylindrical lenses that are used in a point-to-point configuration to image the small focal spot of a an X-ray tube on a microchannel plate detector. We describe the steps that led up to the present design and present data from the tests that have been used to identify the properties of the plastic material that make it a suitable X-ray reflector. We discuss two applications of our technology to X-ray missions that are designed to address some of the scientific priorities set forth in NASA's long term plans for high energy astrophysics. One mission will observe in the 1- 10 keV band, the other will extend up to ca. 100keV.

Historically, segmented optics similar to those used in BBXRT and ASTRO have achieved resolutions of a few arc minutes. Achieving substantially better performance requires significant improvement in both the optics themselves and how the optics are assembled and mounted to flight structure. While techniques for improving the optics themselves are underway at Goddard Space Flight Center (GSFC), Columbia University, and Smithsonian Astrophysical Observatory (SAO), here we address how the optics are assembled and mounted to flight structure. We have developed a concept for mounting large numbers of nested, segmented optics which require sub micron accuracy. This methodology uses lithographically defined and etched silicon alignment microstructure. A precision assembly station, incorporating the silicon micro structures is used to position the optics which are then bonded to a flight structure. The advantages of this procedure are that the flight structure has relaxed tolerance requirements and the precision assembly tooling can be reused. We show the positional requirements of the precision tooling as well as the mechanical requirements of the tooling itself.

We present an overview of our recent progress toward the development of segmented X-ray mirrors for the Constellation-X mission. Our reference design incorporates thin glass reflector substrates, with axially curved X-ray reflecting surfaces applied via epoxy replication. Alignment is accomplished via a precision structure incorporating ultraprecise etched Si alignment microstructures (as described in associated papers). Recent efforts have been devoted to demonstrating that the figure of prototype small segments and the alignment process will allow us to meet the 15" half-power diameter angular resolution requirement. We discuss the status of this, of our efforts to fabricate meter-class segments, and of the developments of supporting metrological techniques. We summarize our plans for a laboratory demonstration of a prototype mirror meeting the Constellation-X angular resolution and weight requirements.

One of the major technological challenges for the Constellation X-ray Mission is the development of light-weight, high-resolution, grazing-incidence optics. NASA's Marshall Space Flight Center is developing and evaluating candidate technologies, based upon full-shell replication off precision mandrels. Here we report on recent progress in meeting the weight and imaging-performance requirements, using very thin, high-strength electroformed nickel alloys. In addition, we briefly describe MSFC's optics fabrication, metrology, and x-ray test facilities.

We describe recent progress toward producing a segmented mirror that meets the mass and angular resolution requirements for the Constellation-X Spectroscopy X-ray Telescope (SXT). While the segmented approach has its heritage in conical thin foil X-ray mirrors pioneered at GSFC, the Constellation-X implementation introduces innovations in nearly all components. The baseline configuration uses thermally formed glass for reflector substrates; thermally formed Be is being investigated as an option. Alignment is performed using etched Si microstructures that locate reflectors to submicron accuracy. The only aspect preserved from previous mirrors is epoxy replication of the X-ray reflecting surface. Thus far, all developments have been at the component level. Nonetheless, we have made substantial progress toward meeting the Constellation-X SXT angular resolution goal.© (2000) COPYRIGHT SPIE--The International Society for Optical Engineering. Downloading of the abstract is permitted for personal use only.

Large scale actuated structures often require piezoelectric elements in the thickness range 10-50μm. For manufacturing purposes, the chemical solution deposition of sol gel composites can create such structures using methods compatible with semiconductor fabrication technology. The piezoelectric characteristics of structures fabricated by patterning methods based on the lapping and dicing of bulk ceramic, spray coating and laser machined and micromolded sol gel composites are compared. Laser interferometer measurements on PZT/PZT composites give d33 = 200 pC/N and d31 = 24 pC/N. The design and fabrication of large area voltage actuated mirrors and annular and linear ultrasonic arrays in the frequency range of 50 MHz are demonstrated.

The Constellation-X Spectroscopy X-ray Telescope (SXT) will provide high-throughput, high-resolution spectroscopy of cosmic sources, from 0.25 keV to 10 keV. Key to this capability is the development of large (1.6 m diameter), lightweight optics for the SXT mirror assembly. Teams led by NASA's Marshall Space Flight Center (MSFC), by NASA's Goddard Space Flight Center (GSFC), and by Italy's Osservatorio Astronomico di Brera (OAB) are currently developing competing mirror technologies for this planned mission. Each team is making significant research progress in developing mirror technologies which satisfy the SXT requirements for lightweight optics, consistent with a system-level optical performance of better than 15 arcsec half-power diameter. The NASA Marshall Space Flight Center (MSFC), in collaboration with the Smithsonian Astrophysical Observatory (SAO), has focussed its efforts on full-shell replicated optics, of electroformed nickel alloys. Recent progress in identifying a surface treatment to effect low, controlled adhesion and, more significantly, in developing new high-strength nickel alloys make this a viable, low cost approach to satisfying the SXT requirements.

CVD SILICON CARBIDE shells have been fabricated by a scalable chemical vapor deposition vapor deposition process to demonstrate the feasibility of producing thin, lightweight optics for x-ray applications. These shells were produced by depositing SiC on shaped graphite mandrels in a CVD chamber, removing the graphite mandrels from SiC deposit followed with controlled machining to produce the required double cone surface. the size of these shells is as follows: diameter equals 250-600 mm, length equals 240-400 mm and thickness equals 1.5-2.7 mm. The roundness of the inside surface of these shells was the inside surfaces of a few shells by the epoxy replication process. Testing of two SiC shells for x-ray applications yielded a half energy width of < 15 arcsecs over a wide field of view. Important issues involved in near-net-shaping and machining of these shells are discussed.© (1999) COPYRIGHT SPIE--The International Society for Optical Engineering. Downloading of the abstract is permitted for personal use only.

Segmented mirrors are one of the two approaches being investigated for both the Spectroscopy X-ray Telescope (SXT) and the Hard X-ray Telescope (HXT) on Constellation-X. Mirrors based on the grazing incidence foil optics pioneered by GSFC will meet the stringent Constellation-X SXT weight requirement, but the currently achieved resolution falls short of the 15 inch half-power diameter (HPD) required for Constellation-X. Significant contributions to the blur arise from the figure of individual reflectors and from inaccurate mounting. Only a small contribution to the HPD of the existing mirrors arises from the conical approximation. In this paper, we describe our program for improving the spatial resolution of segmented mirrors to meet the COnstellation-X requirement. Our effort incorporates accurately figured replication mandrels, mechanically more robust reflector substrates, high accuracy alignment, and ultimately a transition from conical to curved reflecting surfaces.© (1999) COPYRIGHT SPIE--The International Society for Optical Engineering. Downloading of the abstract is permitted for personal use only.

We discuss the x-ray measurement of the focus and alignment of the AXAF (Advanced X-ray Astrophysics Facility) x-ray optics. The high resolution mirror assembly (HRMA) consists of four nested Wolter type I x-ray optics. The attainment of the program goals for high resolution imaging requires that the mirror foci be coincident, both axially and laterally; in addition, the relative tilts between optics within each mirror pair must be small. The mirror tilts and the parfocalization were measured at the X-Ray Calibration Facility (XRCF) at the Marshall Space Flight Center in Huntsville, Alabama during a series of tests in the winter/spring of 1996/1997. The x-ray measurements are compared to the optical alignment data obtained by Eastman Kodak using the HRMA Alignment and Test System (HATS) during HRMA assembly. From these data a preliminary model for the relative location and rigid-body orientation of the individual mirror elements is developed; this mirror model is a component of the SAO high fidelity HRMA raytrace model.

We discuss the ring focus measurements for the Advanced X-ray Astrophysics Facility (AXAF) x-ray optics -- the high resolution mirror assembly (HRMA). The HRMA is an assembly of four pairs of nested Wolter Type-I grazing incidence mirrors coated with iridium (Ir). The ring focus measurements are an essential part of the AXAF ground calibration carried out at the X-Ray Calibration Facility (XRCF) at the Marshall Space Flight Center (MSFC) in Huntsville, Alabama. The ring focus measurements reveal aspects of the test system distortions and the mirror surface figures which are difficult or impossible to detect in the focal plane. The measurement results show periodic modulations of the ring width which was caused by gravity and strain in the epoxy bonds that are part of the mechanical support system. The strongest component of the modulation has 12-fold symmetry due to the 12 flexures that support each mirror shell. We discuss the ring focus model and compare it with the test results to understand the test system distortions an the mirror glass imperfection, and to predict the impact for the AXAF mirror on-orbit performance.© (1997) COPYRIGHT SPIE--The International Society for Optical Engineering. Downloading of the abstract is permitted for personal use only.

The NASA Advanced X-ray Astrophysics Facility-Imaging (AXAF-I), one of NASA's Great Observatories, will be launched in 1998. The AXAF-I High Resolution Mirror Assembly (HRMA) will provide sub-arc second imaging resolution over the expected mission life of five years. During assembly and operational life of the telescope, small dimensional changes of the structural support system can degrade the telescopes resolving power by introducing unwanted forces. The forces that are introduced depend, in part, on the long term temporal dimensional stability of the materials that are used in the telescope. A year-long stability study carried out at the university of Arizona Dimensional Stability Laboratory recently concluded. Cyanate ester-based composites, 7050-T7451 aluminum, LR-35 invar, 6Al-4V titanium, 6061-T6 aluminum and Zerodur were studied. The Zerodur material was found to be stable to better than 0.03 ppm/yr. The titanium was found to be stable to better than 0.5 ppm/yr. The 7050- T7451 aluminum and cyanate ester-based composites were found relatively unstable but their instability improved significantly with time. Monte-Carlo and deterministic techniques were used to predict the effects of the instability on the telescopes' performance. Temporal instability effects were within the systems top level requirements.

Correlation of RTV properties to test dataand its effect on the AXAF mirror performanceSimon C. F. ShengSystems EngineeringOscar BerendsohnConsultantReliability, Materials, System Safety EngineeringMartin R. SchreibmanSpace Science DirectorateHughes Danbury Optical Systems, Inc. (HDOS)lee Wooster Heights, Danbury, Ct. 06810Lester H. CohenSmithsonian Institution/Astrophysical Observatory60 Garden Street, Cambridge, MA 02138ABSTRACTUsing RTV rubber as an interface between mirror elements andtheir supporting structures during grinding and polishing wasproposed for the Advanced X-ray Astrophysics Facility (AXAF) forglass safety concerns. This paper shows that the mirrorperformance is quite sensitive to the compression modulus of GERTV-60 which, like all other rubber-like materials, is verydifficult to characterize by testing and even more difficult tocharacterize analytically. Consequently, using representativeRTV properties in mirror analyses only produces nominalperformance predictions. The envelope of the range ofperformance has to be determined by using both extremes of theRTV compression modulus.This paper also presents a comparison between compressionmoduli generated via testing and that from semi-empiricalformulas. The agreement is satisfactory when mean values of thetest data are used for comparison and the shape factor ismodified to include partially constrained surfaces. The scatterranges from 7.6% to 23.0% depending upon the way the RTV sampleswere cast. Using an error of about 16.2, we were still able tomeet the error budget requirements for the Glass Support Fixture

A methodology is described which minimizes optics distortion in the fabrication, metrology, and launch configuration phases. The significance of finite element modeling and breadboard testing is described with respect to performance analyses of support structures and material effects in NASA's AXAF X-ray optics. The paper outlines the requirements for AXAF performance, optical fabrication, metrology, and glass support fixtures, as well as the specifications for mirror sensitivity and the high-resolution mirror assembly. Analytical modeling of the tools is shown to coincide with grinding and polishing experiments, and is useful for designing large-area polishing and grinding tools. Metrological subcomponents that have undergone initial testing show evidence of meeting force requirements.

We provide an overview of the Constellation-X SXT development program. We describe the performance requirements and goals, and the status of the technology development program. The SXT has a 1.6-meter diameter, a 10-meter focal length, and is to have an angular resolution exceeding 15 arc seconds. It has a modular design, incorporting lightweight, multiply nested, segmented Wolter Type I x-ray mirrors. All aspects of the design lend themselves to mass-production. The reflecting surfaces are produced by epoxy replication off precision mandrels onto glass substrates that have been accurately formed by thermal slumping. Coalignment of groups of relfectors to the required sub-micron accuracy is assisted by precison silicon micorstructures. Optical alignment is performed using the Centroid Detector Assembly originally developed for aligning the Chandra mirror. Recent efforts have concentrated on the producotin of an Engineering Unit, incorporating the components for the first time into a flight-like configuration. We summarize the status of the development of the processes for the key components and the initial metrology results of the Engineering Unit.

We report on progress in developing low-cost methods for shaping thin-foil glass x-ray optics. Such optics might serve as substrates for reflection gratings or as foil mirrors in high-throughput missions such as Constellation-X. Novel thermal shaping to lithographically defined pin chucks leads to the desired shape with high accuracy, thereby avoiding the need for replication. To demonstrate this method we have produced 200 micron-thick glass sheets with sub-micron flatness and half power diameter below 10 arc seconds. We also present a process for depositing low-stress metallic coatings that provides high x-ray reflectivity without significant foil distortion.

Achieving arcsecond angular resolution in a grazing-incidence foil optic X-ray telescope, such as the segmented mirror approach being considered for the Constellation-X Spectroscopy X-Ray Telescope (SXT), requires accurate placement of individual foils. We have developed a method for mounting large numbers of nested, segmented foil optics with sub- micrometer accuracy using lithographically defined and etched silicon alignment micro-structures. A system of assembly tooling, incorporating the silicon micro-structures, is used to position the foils which are then bonded to a flight structure. The advantage of this procedure is that the flight structure has relaxed tolerance requirements while the high accuracy assembly tooling can be reused. A companion paper by Bergner et al. discusses how our process could be used for the SXT. We have built an assembly truss with a simplified rectilinear geometry designed to experimentally test this alignment and mounting technique. We report results of tests with this system that demonstrate its ability to provide sub- micrometer alignment of rigid test optics.