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Thermoelectric generator is a device taking advantage of the temperature difference in thermoelectric material to generate electric power, where the higher the temperature difference of the hot-cold ends, the higher the efficiency will be. However, higher temperature or higher heat flux upon the hot end will cause strong thermal stress which will negatively influence the lifecycle of the thermoelectric module. This phenomenon is very common in industrial applications but seldom has research work been reported. In this paper, numerical analysis on the thermodynamics and thermal stress performance of the thermoelectric module has been performed, considering the variation on the thickness of materials; the influence of high heat flux on thermal efficiency, power output, and thermal stress has been examined. It is found that under high heat flux imposing upon the hot end, the thermal stress is so strong that it has a decisive effect on the life expectation of the device. To improve the module’s working condition, different geometrical configurations are tested and the optimum sizes are achieved. Besides, the side effects on the efficiency, power output, and open circuit voltage output of the thermoelectric module are taken into consideration. [ABSTRACT FROM AUTHOR]