<p>The present study concerns understanding the microstructure, mechanical properties, and corrosion behavior of aluminum cenosphere composite foam developed by plasma-spray-assisted additive manufacturing. Aluminum and cenosphere in the ratio of 9:1, 7:3, and 6:4 were used as feedstock powder for processing. Followed by the development of coupons, the samples were subjected to density measurement, microstructural observation by field emission scanning electron microscopy, and phase analysis by x-ray diffraction technique. Mechanical properties in terms of microhardness and compressive strength were determined by a Vickers microhardness tester and universal testing machine, respectively. Finally, the wear and corrosion resistance properties of fabricated coupons were evaluated in detail. There is a formation of composite foam with reduced density (2.03-1.83 g/cm³ as compared to 2.7 g/cm³ for c.p Al), improved hardness (56-66 HV as compared to 39 HV for c.p Al), a varied compressive strength, improved wear resistance (by 4.56 times as compared to c.p Al), and corrosion resistance (1.8 times as compared to c.p Al) than commercially pure aluminum.</p>