This study investigates the synthesis and characterization of hydroxyapatite (HA)-based composites reinforced by aluminum (Al) for biomedical applications. A self-propagating intermediate-temperature synthesis (SIS) technique was utilized, incorporating magnesium (Mg) as a wetting agent to improve the ceramic-to-metal interfacial bonding. The compaction stage was assessed through finite element modelling using ANSYS software to evaluate pressure distribution, while the microstructural analysis was conducted via X-ray diffraction (XRD). Simulations indicated a non-uniform stress distribution, with stress intensification concentrated at the core of the pellet. An increase in Al content notably enhanced surface features, minimized porosity, and facilitated densification. XRD results verified the development of Al oxide phases and microstructural refinement under various compaction conditions. These outcomes underline the importance of accurately regulating both the compaction pressure and Al content to maximize the mechanical performance of HA-Al composites. The resulting materials exhibit promising properties for applications in load-bearing biomedical implants where mechanical strength and biocompatibility are essential.