In this paper, we systematically investigate three different routes of synthesizing 2% Na-doped PbTe after melting the elements: (i) quenching followed by hot-pressing (QH), (ii) annealing followed by hot-pressing, and (iii) quenching and annealing followed by hot-pressing. We found that the thermoelectric figure of merit, zT, strongly depends on the synthesis condition and that its value can be enhanced to ∼2.0 at 773 K by optimizing the size distribution of the nanostructures in the material. Based on our theoretical analysis on both electron and thermal transport, this zT enhancement is attributed to the reduction of both the lattice and electronic thermal conductivities; the smallest sizes (2∼6 nm) of nanostructures in the QH sample are responsible for effectively scattering the wide range of phonon wavelengths to minimize the lattice thermal conductivity to ∼0.5 W/m K. The reduced electronic thermal conductivity associated with the suppressed electrical conductivity by nanostructures also helped reduce the total thermal conductivity. In addition to the high zT of the QH sample, the mechanical hardness is higher than the other samples by a factor of around 2 due to the smaller grain sizes. Overall, this paper suggests a guideline on how to achieve high zT and mechanical strength of a thermoelectric material by controlling nano-and microstructures of the material.waste heat recovery | energy harvesting A thermoelectric (TE) device is a solid-state device that converts heat directly into electricity and vice versa (1-5). As there are no moving parts involved and the device configuration is simple, TE devices have demonstrated long-term reliability in various space missions, usually running for tens of years without maintenance (6). However, they are not yet widely used in many other energy conversion applications on earth mainly due to their low conversion efficiencies. The conversion efficiency of a TE device largely depends on the material properties, i.e., the figure of merit (1, 3), zT = [S 2 /ρ(κ L + κ e )]T, where T is the absolute temperature, S is the Seebeck coefficient, ρ is the electrical resistivity, and κ L and κ e are, respectively, the lattice (or phonon) and electronic thermal conductivities. Increasing the zT has proven challenging because the constituent TE properties are interdependent; for example, decreasing the electrical resistivity results in decreasing the Seebeck coefficient and increasing the electronic thermal conductivity.