Bruno Correia wrote:

Are instruments, in general, built to work at a certain frequency?

That would be ideal but difficult to implement in reality; therefore they _happen_ to sound better at certain frequenc(ies), not obligatory those intended ...
Recently I started to tune my five course guitar in 415, but I think the sound 
is a bit muffled...

It may simply be because you are used to it being tuned higher up. A lot 
depends on your actual guitar model and string length of course. Say, for a 
'typical' 17th century guitar, with 68 - 69 cm SL, tuning it in E (a' 440) 
would certainly be too high sound-wise (well, at least in my experience), a' 
415 is better, a' 392 is even better still.

Should I use thicker gauges?

Yes.

AB



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