A nasal dilator comprises a laminate of vertically stacked layers forming a unitary, or single body, truss where each layer includes at least one member. The truss features horizontal regions adapted to engage outer wall tissues of first and second nasal passages and to traverse the bridge of a nose therebetween. When in use the dilator acts to stabilize and/or expand the nasal outer wall tissues and prevent said tissues from drawing inward during breathing. Manufacturing methods produce dilator layers and/or finished nasal dilator devices efficiently at the same or lower cost as traditional methods by fabricating dilator elements in whole or part along common lines or edges. Said common lines define peripheral dimensions and form spaced apart relationships between dilator layers, members and finished dilator devices without sacrificing usable material to do so. Manufacturing steps include cutting through a fabrication laminate along lines defining at least portions of one or more layers, members, and the trusss peripheral edges. Manufacturing methods further maximize material usage by incorporating waste material into a subsequent fabrication process. Dilator embodiments further include means for providing disparate dilating force to opposing nasal passages, and means for incorporating promotional printing into the dilator fabrication process.
