A novel method has been proposed to prepare porous materials through deposition of semi-molten particles by flame spraying. In this study, it was found that the porous material was deposited by the stacking of semi-molten particles which were welded by the molten fraction to form a large and strong inter-particle bonding neck between deposited particles. In order to reveal the effect of inter-particle bonding on the compressive behavior of porous Mo, the deposits were investigated by altering the bonding through vacuum sintering of porous Mo with different porosities. Results showed that the sintering temperature and time influenced the bonding significantly and subsequently influenced the properties of flame-sprayed porous Mo deposits. The oxides formed during flame spraying were effectively reduced under hydrogen atmosphere. In addition, the inter-particle bonding and compressive properties of flame-sprayed porous Mo were significantly improved by optimizing the sintering temperature and the heat treatment time.