USB flash drive unable to format

A USB flash drive that won’t format can be incredibly frustrating. You may encounter errors like “Windows was unable to complete the format,” or the drive may appear as write-protected, RAW, or with no capacity. This issue can result from logical corruption, bad sectors, malware infection, or even physical damage. Regardless of the cause, the problem prevents you from using the drive normally for storage, data transfer, or booting.

Chapter 1: Why a USB Flash Drive Won’t Format

Before diving into solutions, it’s important to identify the potential causes behind a USB drive’s formatting failure.

1.1 Common Reasons

Write protection enabled on the drive.

File system corruption (RAW or unknown format).

Bad sectors or logical damage.

Malware infection locking the disk.

Drive in use by another process.

Physical damage to the USB chip or connector.

1.2 Typical Error Messages

“Windows was unable to complete the format.”

“The disk is write protected.”

“Please insert a disk into removable disk.”

“Cannot format drive: device is in use.”

Chapter 2: Preliminary Checks and Quick Fixes

2.1 Try Another USB Port or Computer

First, rule out system-specific errors:

Plug the USB into a different port.

Try a different PC or OS (Windows/macOS/Linux).

Check if the drive is recognized.

2.2 Scan for Malware

A malware infection may block formatting:

Use trusted antivirus software (like Malwarebytes or Bitdefender).

Fully scan the USB drive and your computer.

2.3 Disable Write Protection

2.3.1 Physical Lock Switch

Some USB drives have a switch. Make sure it’s in the unlocked position.

2.3.2 Using Diskpart (Windows)

Open Command Prompt as administrator.

Type:

bash

CopyEdit

diskpart list disk select disk X attributes disk clear readonly

Replace “X” with the USB disk number.

Exit and try formatting again.

Chapter 3: Format via Disk Management

3.1 Steps to Format

Right-click This PC > Manage > Disk Management.

Locate your USB.

Right-click and choose Format.

Choose FAT32. exFAT, or NTFS.

Click OK.

3.2 If Format Option is Greyed Out

Delete the existing volume.

Recreate it by right-clicking > New Simple Volume.

Chapter 4: Format with Command Prompt

Sometimes Disk Management doesn’t work, but Command Prompt does.

4.1 Use Diskpart to Format

Open Command Prompt as admin.

Run:

pgsql

CopyEdit

diskpart list disk select disk X clean create partition primary format fs=fat32 quick assign exit

4.2 Clean vs Full Format

clean: Removes all partitions and file system.

format: Builds a new file system.

This is particularly helpful if the USB shows 0 bytes or is RAW.

Chapter 5: Use Third-Party Formatting Tools

When Windows tools fail, try reliable third-party utilities.

5.1 HP USB Disk Storage Format Tool

Designed specifically for USB formatting.

Supports FAT32. NTFS, exFAT.

Can often override low-level corruption.

5.2 Rufus

Primarily used to create bootable USBs.

Can perform low-level format.

Useful for drives that are unreadable or incorrectly partitioned.

5.3 SD Card Formatter

Designed for SD cards but can work on USB flash drives.

Sometimes corrects controller-level formatting errors.

Chapter 6: Format via Linux Live CD/USB

Linux can bypass some Windows limitations.

6.1 Use GParted

Boot into a Linux distro (like Ubuntu) using a Live USB.

Open GParted partition editor.

Locate your USB.

Delete partitions, create new ones, and format as FAT32 or NTFS.

Linux can often access and fix drives that Windows considers “dead.”

Chapter 7: Low-Level Formatting

If none of the above works, a low-level format might help.

7.1 What is Low-Level Formatting?

It rebuilds the storage structure at the sector level.

Removes bad sectors and resets firmware mappings.

7.2 Use HDD Low Level Format Tool

Select USB drive.

Perform a low-level format (note: this erases all data).

Reformat with Disk Management afterward.

Chapter 8: Repair File System Before Formatting

If the file system is corrupted, try repairing it before formatting.

8.1 Run CHKDSK

Open Command Prompt.

Run:

bash

CopyEdit

chkdsk X: /f /r

Replace “X” with the USB drive letter.

Try formatting again after repair.

Chapter 9: Fix “RAW” or “Unallocated” USB Flash Drives

9.1 Signs

Appears as RAW in Disk Management.

Shows 0 bytes capacity.

Cannot be opened or formatted.

9.2 Solutions

Use Diskpart or GParted to delete partitions.

Create new primary partition.

Format via Windows or a third-party tool.

Chapter 10: Advanced Troubleshooting

10.1 Use Device Manager

Go to Device Manager > Disk Drives.

Right-click USB > Uninstall device.

Reconnect and retry formatting.

10.2 Update or Rollback Drivers

Device Manager > USB Controller.

Right-click > Update Driver or Roll Back.

Chapter 11: When Formatting Fails Due to Hardware Damage

If your USB has physical defects (e.g., NAND degradation, controller failure), software tools won’t help.

11.1 Warning Signs

Device heats up when plugged in.

Flash drive intermittently disappears.

LED activity is erratic.

11.2 Use Manufacturer Tools

Some USB manufacturers provide their own repair tools:

SanDisk: SanDisk RescuePRO

Kingston: Kingston Format Utility

Transcend: JetFlash Online Recovery

These tools can perform low-level formatting or firmware restoration.

11.3 Final Option: Professional Recovery Services

If the drive is important and all else fails:

Contact DriveSavers, Gillware, or Ontrack.

These companies specialize in flash memory recovery.

They have cleanroom environments to extract data from damaged chips.

Chapter 12: Panda Data Recovery for USB Drive Files

If you’re worried about losing files when formatting a corrupted drive, Panda Data Recovery can help you recover files before formatting.

Key Features:

Deep scan of unreadable or damaged USBs.

Supports photos, documents, videos, and more.

Preview before recovery.

Steps:

Launch Panda Data Recovery.

Select the USB flash drive.

Choose Deep Scan.

Recover important files before attempting any format fixes.

Chapter 13: Prevention Tips

Once you’ve resolved your issue, follow these best practices to avoid future problems:

13.1 Always Eject Properly

Click “Eject” before removing the drive. Prevents file system corruption.

13.2 Avoid Sudden Power Loss

Don’t use flash drives with unstable computers or during power interruptions.

13.3 Backup Important Data

Use cloud storage or external backups for critical files.

13.4 Use Quality Drives

Avoid generic, no-name brands. Stick to known names like SanDisk, Kingston, and Samsung.

A USB flash drive that cannot be formatted doesn’t necessarily mean it’s unusable. Most cases can be resolved using built-in tools like Disk Management or Diskpart, third-party utilities like Rufus or GParted, or even professional low-level format tools. If formatting still fails, it’s a sign of more serious physical damage, and professional recovery might be the only option.