The Halbach array magnetic system is the core component of permanent magnetic levitation systems, and its geometric parameters have a decisive impact on the levitation performance and economic efficiency. In this study, a new metric called magnet utilization efficiency is proposed to evaluate the economic use of magnets. Then, combined with finite element analysis and the response surface method (RSM), the influence of the structural parameters on the levitation force and magnet utilization efficiency was revealed. The constructed regression models exhibited excellent predictive performance (Levitation Force Model: R2 = 0.9906, Adjusted R2 = 0.9829, and Predicted R2 = 0.9511; Efficiency Model: R2 = 0.9911, Adjusted R2 = 0.9838, and Predicted R2 = 0.9535), thereby verifying the reliability of the models. Dimensionality reduction analysis of the regression models shows that the levitation force is proportional to the geometric parameters, whereas flatter magnets have a higher magnet utilization efficiency. Furthermore, a multi-objective genetic algorithm (MOGA) was employed to obtain the Pareto optimal front, which reflects the trade-off relationship between the two objectives. Finally, the optimized 160-ton permanent magnetic levitation system achieves a dual breakthrough: under the same levitation force condition, the efficiency increases by 50%, and when maintaining the baseline efficiency, the levitation force increases by over 30%. These results provide a theoretical basis and engineering reference for the design and optimization of magnetic levitation systems.