The success of orthopedic implants critically depends on achieving mechanical and biological compatibility with bone tissue. Traditional titanium implants often suffer from high stiffness, which induces stress shielding, a phenomenon that compromises implant integration and accelerates prosthetic loosening. This study introduces an innovative approach to mitigate these limitations by engineering a porous titanium substrate with a controlled microstructure. Utilizing sodium chloride as a spacer holder, an elution and sintering process was applied at 1250 °C under high vacuum conditions to reduce the material’s elastic modulus. By manipulating NaCl volume fractions (20%, 25%, 30%, and 35%), porous titanium samples were created with elastic moduli between 16.37 and 22.56 GPa, closely matching cortical bone properties (4 to 20 GPa). A hydroxyapatite coating applied via plasma thermal spraying further enhanced osseointegration of the material. Comprehensive characterization through X-ray diffraction, scanning electron microscopy, and compression testing validated the material’s structural integrity. In vitro cytotoxicity assessments using osteoblast cells demonstrated exceptional cell viability exceeding 70%, confirming the material’s biocompatibility. These findings represent a significant advancement in biomaterial design, offering a promising strategy for developing next-generation joint prostheses with superior mechanical and biological adaptation to bone tissue.

The stress shielding phenomenon causes bone deterioration generating problems in joint prostheses, this phenomenon is caused by the difference in stiffness between titanium element and bone [ 1], so it is sought to generate a porous material to reduce the elastic modulus of the material. The spark plasma sintering (SPS) technique is proposed since it allows working with much shorter times and lower temperatures than conventional sintering techniques [ 2].