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The COVID-19 pandemic has led to a greater need for non-transmissible products like face masks, which are effective in preventing the spread of the virus but come with challenges such as reduced breathability and biohazard waste. This study addressed these issues by integrating green-synthesized zinc oxide particles and Azadirachta indica extract into nonwoven face masks. Eight samples were developed using the needle punching nonwoven method and then calendared. These samples were coated with varying levels of A. indica extract (0, 15, and 30 wt.%) and ZnO particles (0, 2, and 4 wt.%) using the dip and dry method. Comparative analyses were performed with market-available masks (MA) and untreated masks (US) for air permeability, thermal resistance, tensile behavior, and antimicrobial efficacy against Staphylococcus aureus. The untreated masks had the highest air permeability at 826 mm/s, which decreased with higher A. indica and ZnO concentrations. Scanning electron microscope (SEM) images confirmed even distribution of ZnO particles. Thermal resistance and tensile properties were directly linked to A. indica and ZnO concentrations. The sample treated with 30 wt.% A. indica and 4% ZnO showed the highest thermal resistance (0.042 m2K/W), elongation (92% CD, 84% MD), and tenacity (0.93 g/tex CD, 0.87 g/tex MD). Increased A. indica and ZnO concentrations demonstrated significant antimicrobial activity, with a maximum zone of inhibition of 8.03 mm recorded at 30 wt.% A. indica and 4 wt.% ZnO particles. These findings suggest potential applications for developing surgical facemasks with improved efficacy. [ABSTRACT FROM AUTHOR]