Additive manufacturing, particularly fused deposition modelling (FDM), has gained increasing attention in aerospace applications due to its capability to produce complex geometries with reduced material usage, making it a promising approach for manufacturing lightweight yet strong unmanned aerial vehicle (UAV) parts. In this study, an integrated framework was developed to optimize FDM parameters for producing UAV parts that are both lightweight and high in strength. A response surface methodology was used to analyze the effects of infill percentage, layer height, number of walls, and build plate temperature on the mass and tensile strength of the printed parts. Two regression models with high predictive accuracy were constructed (R2 = 98.2% for mass, R2 = 88.5% for tensile strength). A multi-objective optimization approach was applied, using the non-dominated sorting genetic algorithm II Pareto front analysis in combination with Minitab’s Response Optimizer tool, to identify the optimal combination of parameters. The results showed that layer height, number of walls, and infill percentage, along with their interaction effects and quadratic effects, had the most significant effects on both mass and tensile strength, whereas build plate temperature had negligible effects. The results from the Pareto front analysis revealed the trade-off between minimizing mass and maximizing tensile strength for the parts. The optimal parameter settings (e.g., 58.26% infill percentage, 0.1635-mm layer height, 4 walls, and 65°C build plate temperature) achieved a tensile strength of 47.08 MPa and a mass of 1.60 g, offering a well-balanced strength-to-weight ratio suitable for UAV applications.