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Abstract The unprecedented COVID-19 pandemic has caused socioeconomic, physical, mental, and environmental upheaval. Personal protective equipment, such as face masks, was mandatory to curb the spread of the virus. The unexpected increase in demand for face masks resulted in an alarming increase in plastic waste globally. The non-biodegradable nature of the raw materials and the potential threat of microplastic pollution amplify the problem. This puts a lot of pressure on policymakers and the global supply chain to develop long-term plans to make face masks less harmful. By reviewing existing life cycle assessment studies, this study aims to provide an overview on how sustainable face masks are. Various challenges in the facemask industry such as microplastic pollution and waste management are discussed. A critical analysis on the various process hotspots is also conducted. Recommendations from this study can motivate focused research into an important field and enable the transitions towards a sustainable facemask industry.