Reconfigurable freeform optical systems enable greatly enhanced imaging and focusing performance within non-symmetric, compact, and ergonomic form factors. In this paper, several improvements are presented for the design, test, and data analysis with these systems. Specific improvements include definition of a modal G and C vector basis set based on Chebyshev polynomials for the design and analysis of non-circular optical systems. This framework is then incorporated into a parametric optimization process and tested with the Tomographic Ionized-carbon Mapping Experiment (TIME), a reconfigurable optical system. Beyond design, a reconfigurable deflectometry system enhances metrology to measure a fast, f/1.26 convex optic as well as an Alvarez lens. Further improvements in an infrared deflectometry system show accuracy around /10 of the notoriously difficult low-order power. Working together, the mathematical vector polynomial set, the programmatic optical design approach, and various deflectometry-based optical testing technologies enable more flexible and optimal utilization of freeform optical components and design configurations.