Higher manganese silicide (HMS) is considered as a promising thermoelectric material at intermediate temperatures. Samples of Si-rich HMS were prepared by arc melting followed by ball milling combined with densification by an induction hot uni-axial pressing (HP) and spark plasma sintering (SPS), respectively. Powder X-ray diffraction, SEM and EPMA studies confirmed the presence of Si in HMS matrix. TEM micrographs on milled powders further confirmed the presence of Si particles with an average size of ~5–10 nm in HMS matrix. Microstructure investigations on densified samples revealed that SPS process seems to be a beneficial tool for embedding the nanostructures of Si (~20–50 nm) particles in HMS matrix. SPS also controls the grain growth of HMS during densification, which in turn reduces the total thermal conductivity from ~4.4 W/m.K to 2.10 W/m.K. On the other hand, samples processed by HP showed the value of ~2.44 W/m.K with similar sintering parameters as in SPS used for densification. Huge reduction in lattice thermal conductivity of about ~55%, and a considerable increase in Seebeck value was observed in Si-rich BMed HMS. However, reduction in electrical conductivity associated with insulating Si particles in HMS matrix limited the zT to ~0.26 at 725 K.Read less <