Hi,
1. There is little difference between optical and electrical cords if they are properly manufactured. Electrical cables might have more physical strength against getting snagged in your other gear. But thereafter the cable might be less reliable.
2. I wouldn't add vacuum pressure for deeper dives. It increases pressure difference between the inside and outside of the housing and thus could slightly reduce MOD for the housing. E.g. a housing with 100m specs and a normal 0.2 bar vacuum, would, in theory, reduce to MOD 98m if you increase the vacuum to 0.4 bar. Increasing vacuum is totally unnecessary unless you have trouble of a vacuum sensor circuit not being temperature compensated. Then you might receive false alarms when descending into colder water, if you pump just to the minimum threshold in room temperature.
3. Strength of small components is not likely to be a limiting factor.
4. Condensation risk is dependent on temperature difference, air moisture (when closing housing) and housing material. A metal housing will conduct heat/cold faster and therefore the metal parts will sooner become cold than the dome, thus collecting the majority of moisture and reducing likelihood of condensation in the dome area. Depth will affect only via water temperature. E.g. here in Finland almost all diving to anything deeper than 30m will be around 4-6 degrees celsius. However, even with a metal housing, condensation is possible if you do not pay attention to closing procedures. E.g. if you are sweating in a 30+ celcius climate and place the camera into the housing with sweaty hands and drip some of your sweat into the housing and then leave the housing in the sun for a while, all that moisture will become partial pressure steam into the air of the housing. If you then make a fast descent to 4 degree water, you might have condensation even inside the dome. (done that).
5. The manufacturer should specify depth ratings for each dome model separately. Please note that there are both glass and acrylic domes that are specified to only 40m. However, the depth rating is for a new dome without scratches and/or microcracks. These faults are likely to decrease depth tolerance.
6. The viewfinder falls under the small components topic. It is the outer glass that takes the pressure difference. In most cases it is straight glass with sufficient thickness. However, I want to point out that in some housing the view finder is attached to an acrylic back window. If you use a longer 45 or 180 degree viewfinder on your housing and you happen to bump a tank against the viewfinder, there will be momentary dynamic forces in addition to the static water pressure.
7. The back window is designed by the housing manufacturer to be thick enough. In most cases it is a straight acrylic sheet without curvature and most of them range between 5-10 mm thickness. In addition to thickness, the critical design question is the surface area. It is often the surface area of the acrylic window that will limit the maximum depth. This is quite apparent for Blackmagic camera housings and some of the monitor/recorder housings, especially one with larger screen size.
8. Different manufacturers have different procedures for this. For example, some manufacturers just perform a test to this nominal depth, but, design and manufacture all the items robust enough for much bigger depths. They just don't claim any higher figures. In Europe/EU there is regulation concerning pressure vessels and how the maximum operational pressure and test pressure should relate to each other. I wonder how many, if any, of the manufacturers have paid attention to these rules.
We perform hydrostatic testing for our customers' u/w camera gear and do perform various kinds of tests upto static pressures matching 150m water depth. However, these are static tests. If you bump your acrylic (or glaas) dome into a tank, DPV, ship wreck or solid rock at 150m depth, there will be the combined effect of static and dynamic forces at very small points of contact and an implosion is possible. Some of our customers have been shooting stuff at 150m and I have warned them about this combined risk.