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.© (2002) COPYRIGHT SPIE--The International Society for Optical Engineering. Downloading of the abstract is permitted for personal use only.