Dedicated to Professor Mercouri Kanatzidis on the occasion of his 65th birthdayFor mass production of thermoelectric generators, a cheap/ sustainable method is required to fabricate leg material with a high figure of merit, ZT. Severe plastic deformation, SPD, increases the defect density, and in parallel decreases the grains to nano-size. SPD via high-pressure torsion, HPT, was used to process hot pressed discs, whereby the Seebeck coefficient remained unchanged and the enhanced electrical resistivity was overcompensated by a low thermal conductivity, resulting in a raise of ZT. Secondly, cold pressed commercial p-and n-type skutterudite-powder was deformed via HPT, exhibiting higher ZT values than the hot-pressed reference samples. This method was upscaled to samples of 30 mm diameter (heights: 1 mm, 8 mm). These large samples, enabled to study the influence of shear strain with all its impact on micro-structural, physical and mechanical properties, revealing for the thin samples record high ZTs. Both thick samples showed homogeneous properties and ZTs ~1.3.