Computer-integated safe design of FGM component for hip replacement prosthesis was presented based on principle of optimal stresses distribution in the FGM component. The goals were to create an FGM structure with reasonable compressive stresses on the surfaces (subjected to wear) and to keep them during the entire manufacturing cycle (sintering, machining, assembling and application). The residual stresses developed in the different parts of the composite were implemented into the subsequent process of the surface grinding and assembly to simulate properly the whole processing route to ensure optimal combination of the processing parameters.