Comprehensive review of the material life cycle and sustainability of solar photovoltaic panels

• Reviews solar panel manufacturing, energy matrices, and sustainability aspects. • Compares surveys by focus areas and highlights research gaps. • Evaluates energy use, payback time, and CO₂ emissions for three solar PV types. • Formulates five research questions on process, performance, and efficiency. • Suggests future research on recycling, energy use, durability, and lifespan. Photovoltaic (PV) systems provide a sustainable alternative to fossil fuels due to their low carbon emissions and renewability. This survey followed the Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) methods and proposed five research questions (RQs) to identify sustainable raw material extraction and refinement methods in solar PV technologies. It aimed to determine the best-performing PV systems regarding energy consumption, energy payback time (EPBT), and global warming potential (GWP/CO 2 emissions) across generations, as well as the most efficient PV systems for outdoor use. RQ1 presented environmentally friendly raw material extraction and refinement techniques, such as glycine leaching and ionic liquids, in line with Life Cycle Assessment principles and Sustainable Development Goal 12. RQ2 indicated that single-crystalline silicon (SC-Si) (19 to 48 GJ/kW), gallium arsenide (GaAs) (10 to 20 GJ/kW), and concentrated photovoltaics (CPV) (4.3 to 13 GJ/kW) had the highest energy demands. RQ3 found that SC-Si (1–4 years), copper indium selenide (1.87–9.44 years), and organic PV cells (0.2–4 years) had the longest EPBTs. RQ4 identified the highest GWP in SC-Si (40 to 60 g CO 2 -eq/kWh), GaAs (40 to 70 g CO 2 -eq/kWh), and perovskite solar cells (20 to 60 g CO 2 -eq/kWh). RQ5 showed that CPV technology had the highest outdoor efficiency at 33 %. After a thorough review, we proposed future research directions, including a list of recyclables, reusable, and disposable materials to enhance PV sustainability, evaluating energy consumption across additional life cycle stages, and developing methods to extend panel lifespan, reduce replacements, and minimize waste.