Abstract: A porous layer of 2mm thick on the end surface of man-made composite hipbone was cooted with Tc4 spherical Titanium alloy powder prepared by plasma rotating electrode process in present study. The present work emphasised the influences of particle size,sintering process and the roughness of matrix surface on the pore size of composite porous layer, porosity and the bonding strength between porous layer and matrix. The mechanical properties of composite porous man-made hipbone were also tested. Experimental results show that the maximum pore size of materials depends mainly on particle size and increases linearly with increase of particle size.The Key factors influencing bonding strength include sintering process and the roughness of matrix surface. Bonding strength enhances with increase of sintering temperature and its holding time, decrease of particle size and the roughness of matrix surface.Porosity depends only on the piled up condition of powder. The mechanical properties obtained from the preparation of man-made hipbone by using composite porous Titanium: σ_b=830~880 MPa, σ_0.2= 810~840 MPa, δ=9.5~12.0, ψ=26.0~33.0%