Traditional strain gauges face challenges such as significant strain transfer errors and slow response during monitoring, severely limiting the engineering effectiveness. To addresses the monitoring requirements for strain, vibration, and clamp looseness in aviation hydraulic pipelines, this paper proposed a design and manufacturing method for in-situ preparation of thin-film strain sensors on hydraulic pipelines. A finite element analysis model for strain transfer errors was established, and the structural parameters of the resistive strain grating were optimized. Multi-layer hetero-thin films, including the Ni80Cr20 strain-sensitive layer, were prepared using magnetron sputtering technology. Through a five-axis laser etching process, the laser incidence angle and focal position were adjusted in real-time, achieving a high-precision control over the etching depth. Testing revealed that the prepared thin-film strain sensor exhibited a drift rate (DR) of 8.4 × 10^-5 h^-1, a temperature coefficient of resistance (TCR) of 1.3 × 10^-4 ℃^-1 in the range of -40 ~ 100 ℃, a gauge factor (GF) of 2.03 in the strain range of 0 ~ 500 με, and a response time of just 15 ns. Force hammer experiments confirmed the sensor's ability to detect and identify key information such as strain, vibration, and clamp tightness. This integrated manufacturing sensor holds promising applications in the field of aviation hydraulic pipeline condition monitoring.