This case report aims to describe novel steps in the digital design/manufacturing of facial prostheses for cancer patients with wide inoperable residual defects, with a focus on a case of a mid-facial defect. A facial scanner was used to make an impression of the post-surgical residual defect and to digitalize it. The daughter’s face scan was used for reconstructing the missing anatomy. Using 3D printing technologies, try-in prototypes were produced in silicone material. The substructure was laser melted. The final prosthesis was relined directly onto the patient’s defect. The prosthesis resulted in a very low weight and a high elasticity of the external margins. The laser-melted substructure ensured the necessary rigidity with minimum thickness.