In this work, micro-plasma spraying is used to produce hydroxyapatite coatings on Ti-6Al-4V substrates. To understand coating formation mechanisms, in-flight particle velocity and surface temperature were monitored under different spraying conditions. XRD measurements show that the resulting coatings have a high degree of crystallinity with little amorphous or metastable phases. Some of the coatings were also found to have a uniformly distributed columnar structure, corresponding to a strong (002) texture and excellent stability in Hanks’ salt solution even after 14 days of immersion.