Poor crystallinity of HA coating accelerates the rate of bioresorption leading to poor adhesion between coating and substrate. This is due to rapid mass loss of HA coatings resulting in poor stability and hence loosening of implants. Therefore, in the present work an attempt is made to improve crystallinity of HA coating using plasma spraying process. To achieve this HA coatings were developed on titanium Grade 2 substrates at various standoff distances in the plasma spraying process. All the HA-coated substrates were characterized using X-ray diffraction and scanning electron microscopy to analyze the phase and microstructure of the HA coatings. The results demonstrate formation a highly crystalline (~90%) and desirable dense bio-active hydroxyapatite coating on the substrate at a standoff distance of 230 mm. In addition to this cell viability test was also carried out on all HA coatings to study cells survival and interaction with coated material.