Titanium and its alloys are attractive materials for biomedical applications. However, Ti tends to react easily with oxygen, resulting in a thick oxidization surface layer. This oxidization layer on the Ti surface impacts the bond strength of the Ti-porcelain prosthetic appliance. Literature studies propose the introduction of an intermediate ceramic coating layer between the Ti substrate and the porcelain to improve Ti-ceramic adhesion. In this work, a process based on covalently attached polymeric sonocatalysed sol-gel zirconia layer on 3D printed grade 5 Ti surface was developed, in order to improve porcelain-substrate adhesion. A ZrO2 sol-gel layer was deposited on Ti as a first layer and yttria stabilized zirconia (YSZ) was plasma sprayed as a second layer before the deposition of the porcelain. ZrO2 sol-gel coatings were prepared from sols under ultrasonication to complete the hydrolysis. Then a dip coating process was employed to coat the Ti substrate, involving its dipping into the final sol for several time frames, followed by controlled ascension. Also, various surface modifications such as sand blasting or chemical treatments were investigated. The morphology and integrity of the coatings-porcelain system were evaluated by SEM and the chemical structure of the coatings, that reveals the coating-substrate adhesion, was investigated by FTIR studies. The main mechanical features of the coating system including the sol-gel, the thermally sprayed and finally the porcelain layers were investigated with particular focus on roughness, thickness, and adhesion to the substrate. Furthermore, the implants were evaluated in vitro in a hip joint simulator machine, according to ISO 14242. By this way, wear and surface roughness were examined during the working conditions of 100,000 and 1,000,000 cycles.