The demand for improved implant performance is placing manufacturers in a position to reassess their processing capabilities and use advanced characterization techniques to explore further characteristics and properties. Thermal spraying is paving the way to a potentially new process for tailored surfaces. Printing through a thermal source offers unique characteristics that cannot be provided by other processes, especially if particles are molten and then resolidified; crystallinity directly impacts the bioactivity and the less commonly measured surface potential can influence cell proliferation. Following the theme of the Scandinavian Society for Biomaterials conference on “Underlying challenges in Biomaterials” this work will investigate the change in printed droplet characteristics and see how the geometry, topography, crystallinity and surface potential change with spray distance.