From childhood until recent surgery (39yo) i had horrible sinus problems that led to the upper sinus cavities puffing out and deforming my forehead. is there a wearable brace to fix? surgery?

Unaware : I'm unaware , but visit a plastic surgeon . I'm sure it would be cosmetic though and you will have to pay.

See below: Is the deformation from the frontal bone expanded or destroyed? Need to make sure that the frontal sinusitis is successfully managed before doing anything. If bone destroyed then titanium mesh with or without bone graft. If bone intact but expanded then would need to be drilled down if not too thin. An external appliance no help. Make sure not acromegaly or other problem like fibrous dysplasia.

DNA appliance: It sounds like you may have an underdeveloped maxilla. There is a doctor in oregon, dave singh, that has developed a pneumopedic device that can aid in correcting sinus issues, tmd, upper airway resistance syndrome, and obstructive sleep apnea. This is a non-surgical device.