Thermal spray coatings consist of aggregates of solidified and flattened droplets. Although research has been directed into the examination of bulk coatings, a recent emphasis has been on examination of individual splats as a means to understand coating properties. In this study the morphology and microstructure of the solidified flattened droplets were examined. The morphology of single, micro-deposited HAp coatings onto commercially pure Ti (CP Ti) was investigated using scanning electron microscopy (SEM). Transmission Electron Microscopy (TEM) in conjunction with Focused Ion Beam (FIB) was used to reveal the ultra-microstructure. Also, the topography of splats sprayed at room temperature, 100 oC and 300 oC was investigated; as was the micromechanical properties of thermally sprayed hydroxyapatite (HAp) splats. The intention was to relate the processing conditions to the splat geometry and, hence, the micro-mechanical characteristics of splats that, together, confer extrinsic properties onto the bulk coating.