SMI has teamed with a leading thermoelectric (TE) research group in order to optimize and convert high-performance TE materials developed in laboratory-scale into economically producible products for NASA missions and commercial applications. Recent results with nanocomposite films have shown that Figures of Merit (ZT) much greater than 1.0 are possible at laboratory-scale; however a technology road map with the view towards large-volume and low-cost manufacturing processes of such TE devices has not previously been envisioned. We propose to develop a scalable manufacturing process of large-volume and cost-effective nanocomposite TE device films with ZT values exceeding 2.0. In Phase I, SMI and our partner will demonstrate a scalable manufacturing technology for nanocomposite films required for high-performance TE devices. In Phase II, we will continue materials development, device optimization, and process scaling to large-scale production. Further, we will market the technology with end product producers. The Phase III result will be the availability of high-performance TE devices that utilize nanocomposite films for NASA applications, commercial uses in general, and the new energy frontier of waste heat recovery.