Thallium doping into lead telluride has been demonstrated to increase the dimensionless thermoelectric figure-of-merit ͑ZT͒ by enhancing Seebeck coefficient due to the creation of resonant states close to Fermi level without affecting the thermal conductivity. However, the process is tedious, energy consuming, and small in quantities since it involves melting, slow cooling for crystal growth, long time annealing, post-crushing and hot pressing. Here we show that a similar ZT value about 1.3 at 400°C is achieved on bulk samples with grain sizes of 3 -7 m by ball milling a mixture of elemental thallium, lead, and tellurium and then hot pressing the ball milled nanopowders. © 2010 American Institute of Physics. ͓doi:10.1063/1.3452323͔Thermoelectrics ͑TEs͒, as one of the most promising approaches for solid-state energy conversion between heat and electricity, is becoming increasingly important within the last decade as the availability and negative environmental impact of fossil fuels draw increasing attention. Various TE materials with a wide working temperature range ͑from 25 to 1000°C͒ for different applications in cooling and power generation have been extensively studied. The efficiency of TE devices is determined by a dimensionless figure-of-merit ZT = ͑S 2 / ͒T, where S is the Seebeck coefficient, the electrical conductivity, the thermal conductivity ͑sum of the electronic part e and the lattice part L ͒, and T the absolute temperature of the material. 1 Lead telluride ͑PbTe͒ is one of the most studied and used intermediate temperature TE materials with a ZT of about 1 at 380°C, 2 which is suitable for power generation applications such as waste heat recovery 3 and potentially in solar energy conversion. 4 However, the toxicity of Pb is a big concern, which slowed down the applications of such materials. Nevertheless, the interest in PbTe has significantly increased due to the demonstration of a ZT higher than 1.5 by creating nanosized inclusions in bulk crystalline materials ͑lead antimony silver telluride͒ using the traditional crystal growth technique, in which the improvement comes from thermal conductivity reduction due to the increased phonon scattering by the nanosized inclusions in the materials. 5 The formation of such inclusions is believed to be caused by substituting some Pb with Ag and Sb.Recently, a ZT of about 1.5 at around 500°C was also reported through improving the Seebeck coefficient 6 via creating resonant states close to Fermi level by using a 2 at. % thallium ͑Tl͒ to replace Pb ͑Tl 0.02 Pb 0.98 Te͒. However, the process is very tedious since it involves melting, slow cooling for crystal growth, long time annealing, post-crushing, and hot pressing for compacting the powders into dense bulk samples. Such a slow process is not practical to large scale production of multiple tons per year required by industrial applications.In the last few years, we have successfully demonstrated that large quantities of bulk nanostructured TE materials can be easily produced by ball milling and hot press...