The work aims to study the spreading and solidification characteristics of plasma spraying droplet in surface textures, and to provide theoretical assistance for understanding the influence of surface texturing on the bonding mechanism of plasma sprayed coating and then improving the bond strength of the coating. Numerical models of droplet filling micro textures during plasma spraying were established by using Flow 3D to analyze the temperature field and spreading characteristics. The temperature field and spreading law of droplet filling sinusoidal texture were studied. The effects of texture bulges and shapes on the above factors were compared. Simultaneously, the effects of different textures on coating microstructure were analyzed based on the plasma spraying experiment on laser textured surfaces. It was found that the heat dissipation rate of the texture without bulges was about 0.7 μs faster than that with bulges. The dimple texture had the minimum dissipation rate, and its maximum temperature is still 44.7 K higher than the droplet liquidus (1728.4 K) at the end of the calculation. The highest temperature of the substrate was about 1680.5 K, which is mainly at the top of the bulges, the inflection point between the substrate plane and the texture wall, and the convex point on the texture wall. The solidified droplet in the sinusoidal texture with bulges gradually become thinner from the middle to both sides, the droplet had a regular disc shape outside the texture without bulges, and there was a “cavity” feature at the bottom of the dimple texture. The cross-section morphology analysis of the coatings showed that the coating on the textured surface with bulges had better morphology, while the coating on the dimple textured surface had more defects and the morphology was the worst. Thus, the Ni-based coating is mechanically bonded to the textured surface. Compared with the dimple texture, the sinusoidal and groove textures are more conducive to the improvement of coating quality, and the existence of texture bulges is also beneficial to the spraying quality.