Ti6Al6V foam materials were prepared with spherical particles in range of 20 90mm. Average porosity under various compaction pressure (200 MPa, 400 MPa, 500MPa, 600MPa, 700MPa), sintering temperature (1000oC-1400oC) and time (4h-6h) was observed in the range of 52%-72%. It was observed that sintered Ti6Al4V foam material can be potentially used for the spinal surgery. Furthermore, strength of the Ti6Al4V foam material in the porosity level of 40% is comparable with the human cortical bone. And also 22 Design of Experiment methods were used to investigate the major affective parameters during the processing of Ti6Al4V spinal cages. According to this investigation, sintering temperature, particle diameter and compaction pressure are the most affective parameters control the over all process of foam production. In the design process, protection case also designed for the foam material to put them inside of it. The reason of producing protection case is that eliminating the particle loosing from the sharp edges of the Ti6Al4V foam material.