When analysing packed beds using CFD approaches, producing an accurate geometry is often challenging. Often a computational model is produced from non-invasive imaging of the packed bed using 3d MRI or ti-CT. This work pioneers the exact reverse of this, by creating a physical bed from the computational model using Additive Layer Manufacturing (ALM). The paper focuses on both experimental analysis and computational analysis of packed columns of spheres. A STL file is generated of a packed column formed using a Monte-Carlo packing algorithm, and this is meshed and analysed using Computational Fluid Dynamics. In addition to this, a physical model is created using ALM on a 3d printer. This allows us to analyse the identical bed geometry both computationally and experimentally and compare the two. Pressure drop and flow patterns are analysed within the bed in detail. (C) 2014 Elsevier Ltd. All rights reserved.