This study investigates the impact of additive manufacturing on the mechanical properties of engineering components, emphasizing the optimization of fabrication process parameters. Standard specimens were fabricated and analyzed, with an experimentally determined maximum tensile strength (TS) of 39.574 MPa at a 0.10 mm layer height and 90° raster orientation. A genetic algorithm was employed to optimize the parameters, predicting a TS of 40.04512 MPa with a 0.12 mm layer height and 89° raster orientation. Experimental validation resulted in a TS of 41.34 MPa, representing a 4.47% improvement over the initial maximum value and a prediction error of 3.13%. These optimized parameters were then applied to fabricate the non-sensing encasing of strain electrodes using ABS material, ensuring enhanced durability and performance with a Fused Deposition Modelling printer. The finalized encasing, following post-processing, is ready for future testing as an embedded strain sensor. The study demonstrates the effectiveness of the optimized parameters in improving TS and their applicability in advanced manufacturing.