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The work presented in this paper demonstrates an experimental path to improve the performance of a screen-printed flexible thermoelectric generator through optimization of leg materials, geometrical and structural parameters of the leg, and the viscosity of screen-printed ink. A thin and porous screen-printed leg structure improves the Seebeck coefficient and power output by 11.53 and 8.52 times, respectively than a thick and denser leg structure. A trapezoidal design increases the Seebeck coefficient, and power output by 2.72 and 3.82 times, respectively, compared with a rectangular leg structure. The observed increment in the power output using silver as contact material is about 2.17 times higher than graphene. Screen ink with higher ink viscosity results in a 47 % reduction of transient thermal conductivity and an increased power factor by 20.33 times. The rectangular leg produces the maximum power factor of 1.30 × 10−12 µWmm−2K−2. The improvement possible in the power output by controlling the leg structure's porosity is around 752.71 %. The result indicates that optimization of ink viscosity and porosity of ink film has significant influence in enhancing the performance of FTEG than its leg shapes and material properties. [Display omitted] • Performance optimization of PANI/Graphite based screen printed FTEG is developed. • Trapezoidal leg shape is preferable over rectangular to enhance the power output. • Influence of ink viscosity is prominent than leg geometry on FTEG performance. • The higher electrical resistance of contact material enhances the voltage output. • Porous ink film reduced thermal conductivity and enhanced power output. [ABSTRACT FROM AUTHOR]