The study of micromechanical behaviour of granular materials has a continuous interest in several engineering fields. Better understanding of the relationship between particle morphology and mechanical performance of such materials is essential in geotechnical applications. Past studies have used discrete element modelling (DEM) to demonstrate the particulate behaviour of granular soils. However, the material properties used as input parameters for DEM simulations are often generalised due to limited data used during calibration and validation exercises. With the advancement of micro-CT scan and 3D printing, improvement can be made to DEM simulations through independent study of particle response for various materials. This paper describes the methodology used to improve DEM simulations and to replicate granular particles by means of 3D printing. Realistic geometric extraction of sand particles was achieved through micro-CT which can then be imported to DEM simulations. To study the influence of particle mineralogy, synthetic particles were produced by means of 3D printing. A range of sintering powders can be used to print particles with various stiffness. The outcomes from the improved DEM models and testing of synthetic printed particles can be used to validate the mechanical behaviour and particle interaction through the independent study of particle morphology, size, angularity, gradation and mineralogy.