Background: Rehabilitation of edentulous postmucormycosis maxillary defects is challenging due to extensive anatomical loss, restricted intraoral access, and financial limitations. Surgical reconstruction or implant-supported prostheses may be contraindicated, while conventional acrylic obturators often fail to achieve retention and stability. Case description: A 67-year-old male with controlled diabetes, previously treated with amphotericin B following COVID-19-associated mucormycosis, presented 3 years postmaxillectomy with complete edentulism and a vertical Class II defect (>50% vertical bone loss). Symptoms included impaired mastication, swallowing difficulty, and social isolation. Prior conventional obturator attempts were unsuccessful. Intervention: Computed tomography (CT) scans (1 mm slices, Siemens Somatom) were processed using RadiAnt, Meshmixer, and Chitubox to generate STL data, which was 3D-printed (Elegoo Mars 3). A wax bulb prototype was sculpted on a 3D-printed model utilizing undercuts for retention and processed with Mollosil silicone (10:1 mix, 10 minutes at 45 °C). A vinyl polysiloxane (VPS) pickup impression enabled fabrication of a definitive heat-polymerized polymethyl methacrylate (PMMA) obturator. Mollosil bulb bonded to acrylic via Mollosil adhesive and mechanical retention. Outcome: The hybrid obturator restored retention, stability, occlusion, speech, and deglutition. Follow-ups at 48 hours, 1 week, 1 month, and 6 months confirmed sustained function, oral–nasal separation, and patient satisfaction without complications. Conclusion: This CT-based hybrid digital–conventional workflow with a flexible Mollosil bulb offers a cost-effective, minimally invasive solution when conventional methods fail.