Background: Large segmental femoral defects following high-energy trauma present a major reconstructive challenge. Options include bone transport, induced membrane (Masquelet) techniques, and vascularised bone transfer, each limited by defect size, treatment duration, and morbidity. Within vascularised reconstruction, strategies include single, double-barrel, or multiple fibula constructs. Optimal management requires orthoplastic collaboration and careful strategy selection. We describe a multidisciplinary approach using double free fibula transfer with virtual surgical planning (VSP) for definitive reconstruction of a complex post-traumatic femoral defect. Methods: A 28-year-old man sustained polytrauma including an open midshaft femoral fracture with 8–12 cm segmental bone loss. Initial intramedullary fixation and cement spacer placement was followed by soft tissue coverage with a contralateral anterolateral thigh (ALT) free flap. Given defect length, geometry, and prior reconstruction, bone transport, Masquelet, and double-barrel fibula were deemed suboptimal. VSP guided design of two independent free fibula flaps, inset as medial and lateral vascularised struts with custom plates. The existing ALT pedicle served as recipient vessels; one flap was anastomosed directly, the second as a flow-through flap. Results: The double free fibula construct restored femoral continuity and stability while preserving soft tissue coverage. Microsurgical anastomoses were completed without complication, and early postoperative assessment confirmed flap viability and stable fixation. Conclusion: Double free fibula transfer, facilitated by VSP and innovative recipient vessel strategies, provides a reliable alternative when bone transport, induced membrane techniques, or double-barrel fibula are unsuitable. This case highlights the value of staged orthoplastic collaboration and strategic decision-making in complex limb salvage.