One-step plasma-activated sintering (OS-PAS) fabrication of single-phase high-performance CoSb 3 -based skutterudite thermoelectric material with a hierarchical structure on a time scale of a few minutes is first reported here. The formation mechanism of the CoSb 3 phase and the effects of the current and pressure fields on the phase transformation and microstructure evolution are studied in the one-step PAS process. The application of the panoscopic approach to this system and its effect on the transport properties are investigated. The results show that the hierarchical structure forms during the formation of the skutterudite phase under the effects of both current and sintering pressure. The samples fabricated by the OS-PAS technique have defined hierarchical structures, which scatter phonons more intensely over a broader range of frequencies and significantly reduce the lattice thermal conductivity. High-performance bulk Te-doped skutterudite with the maximum ZT of 1.1 at 820 K for the composition CoSb 2.875 Te 0.125 was obtained. Such high ZT values rival those obtained from single filled skutterudites. This newly developed OS-PAS technique enhances the thermoelectric performance, dramatically shortens the synthesis period and provides a facile method for obtaining hierarchical thermoelectric materials on a large scale. NPG Asia Materials (2017) 9, e352; doi:10.1038/am.2017.1; published online 24 February 2017 INTRODUCTION Thermoelectric technology uses solid-state semiconductors, which can directly convert heat into electricity and vice versa using the Seebeck effect for power generation and Peltier effect for cooling. The efficiency of thermoelectric materials is governed by the dimensionless figure of merit ZT = α 2 σT/κ, where α, σ, T and κ are the Seebeck coefficient, electrical conductivity, absolute temperature and thermal conductivity, respectively. Many studies have been conducted in the past decades 1-5 to enhance the thermoelectric properties with a focus on improving the power factor and decreasing the thermal conductivity. Because of the high electrical transport performance 6,7 and relatively good mechanical properties, 8 skutterudites are considered notably promising for commercial power generation thermoelectric applications 9,10 in the temperature range of 500-900 K. 6,7,11,12 However, the disadvantage of skutterudites is their notably high lattice thermal conductivity of 410 W m − 1 K − 1 . To obtain a higher conversion efficiency, the thermal conductivity must be further reduced.The thermal conductivity of skutterudites derives from the contributions of phonons with a notably broad range of frequencies and mean free paths (MFPs). [13][14][15][16][17] Those phonons are primarily scattered by features in the structure (dopant, nanostructures and so on) that are comparable in size to the MFP of the phonons. For example, the high-frequency (short-wavelength) phonons tend to be scattered more