Faris was born in Houston, Texas, the son of Kathy Faris. He moved from Houston to Parma, Ohio, at age 12, with his mother after his parents' divorce. He attended Padua Franciscan High School and graduated with honors in 2000.

Faris decided to become an actor at the age of 17. He began his acting and modeling career in Cleveland at Barbizon, and later moved to the International Model and Talent Association with Stone Model & Talent. Three weeks after high school graduation, Faris and his best friend moved to California. Faris was cast in the role of Danny's gunner in Michael Bay's blockbuster war film Pearl Harbor alongside well-known stars Ben Affleckand Josh Hartnett It was this role that started his Hollywood career.

Faris starred in many different projects, including two television shows, Life As We Know It, and Reunion, both canceled before the end of their first season. He also played William Beardsley in Yours, Mine and Ours and he has been a guest star on other television shows.

Faris has also starred in Sleepover with Alexa Vegain 2004. In 2007, Faris went back to work on three back-to-back films, Forever Strong, Never Back Down, and Brooklyn to Manhattan. Never Back Down was released on March 14th, 2008, with the other two films also opening in 2008. Currently, Faris is filming in and producing The Glass Eye with his manager Dino May.

In 2008, Faris won the MTV Movie Award for Best Fight, along with Cam Gigandet in Never Back Down. He stripped for UK Cosmopoltian for a good cause, benefiting his choice of awareness.

May 27, 2008, Sean produced and starred a short film called Manifest Destiny. Release date unknown.