A nasal dilator comprises a laminate of vertically-stacked layers that form a unitary truss. The truss features end regions that engage outer wall tissues of a users nasal passages, joined by an interconnecting region that traverses the bridge of the nose. The dilator acts to stabilize nasal outer wall tissues and prevent them from drawing inward during breathing. Dilator components are sized and shaped to engage the nose and provide effective dilation, and to facilitate lateral and longitudinal registration during manufacture, while reducing material waste. Methods of manufacture include progressive steps to fabricate and assemble components into finished devices. Some partially-assembled embodiments include a final assembly step performed by the user to create a dilator with a customized truss length.
