USB Pen Drive Error: How to Fix “Windows Was Unable to Complete the Format” (2026 Guide)

If you’re facing a USB pen drive error such as “Windows was unable to complete the format”, USB drive not detected, or corrupted USB flash drive, you’re not alone.

These errors are common on Windows systems and usually occur due to file system corruption, unsafe removal, virus infection, or hardware issues.

In this guide, you’ll learn:

• Why USB pen drive errors happen
• How to fix USB pen drive errors step by step
• How to recover a corrupted USB flash drive
• How to prevent USB errors in the future

This guide is written for beginners and everyday users, using simple language and safe methods.

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Common USB Pen Drive Errors on Windows

Older systems may fail formatting due to TPM issues → How to Install Windows 10 on Unsupported Hardware

You may see one or more of these issues:

• Windows was unable to complete the format
• USB pen drive not showing up
• USB drive becomes RAW
• USB device not recognized
• Write-protected USB drive
• Corrupted USB flash drive

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Why USB Pen Drive Errors Occur

If your USB is not detected at all, see 👉 USB Stick Not Recognized as a Bootable Device

USB pen drive errors usually happen because of:

• Unsafe removal of the USB drive
• Power interruption during file transfer
• Virus or malware infection
• File system corruption
• Bad sectors on the USB drive
• Using the USB on incompatible or infected systems
• Low-quality or counterfeit flash drives

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Method 1: Fix USB Pen Drive Error Using Disk Management

This is the first and safest method to try.

Steps:

1. Press Windows + X
2. Click Disk Management
3. Locate your USB pen drive
4. Right-click the USB drive
5. Select Format
6. Choose FAT32 or NTFS
7. Click OK

Method 2: Fix USB Pen Drive Error Using Command Prompt (CMD)

This method fixes deep file system corruption.

⚠️ Warning: Selecting the wrong disk can erase data. Follow carefully.

If CMD fails, your system files may be corrupted → Fix Windows BSOD Errors

Steps:

1. Press Windows + X → Command Prompt (Admin)
2. Type the following commands one by one:

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

Replace X with your USB drive number)

3. Safely remove and reconnect the USB drive

This method fixes most “unable to complete the format” errors.

Method 3: Recover Corrupted USB Pen Drive Using ChipGenius

If formatting fails, your USB controller information may be damaged.

Steps:

1. Download ChipGenius
2. Plug in your USB pen drive
3. Open ChipGenius
4. Note the Chip Vendor ID & Product ID
5. Search for the correct recovery tool using this information
6. Use the tool to repair the USB firmware

📌 This method is useful for Transcend, SanDisk, and generic USB drives.

Open up this website https://www.usbdev.ru/files/smi/smimptool/  find the chip vendor, in my case it is  SMI Chip Vendor and chip Part number is  SM3255AB, Download the latest version software, extract the tool

Remove the USB Drive, before launching the tool, plug in and tool should detect as shown in the image

• On the Tool click on start, this will start to rebuild your pen drive.
• Once tool completes the Repair, you can now format the drive and start storing your files and folder on the USB Pen drive.

Method 4: Fix USB Pen Drive Error Using Third-Party Tools

If Windows tools fail, you can try trusted recovery utilities:

• EaseUS Partition Master
• MiniTool Partition Wizard
• HP USB Disk Storage Format Tool

✔ Use only well-known tools
❌ Avoid unknown “one-click fix” downloads

How to Prevent USB Pen Drive Errors in the Future

Follow these tips to avoid USB problems:

• Always use Safely Remove Hardware
• Never unplug during file transfer
• Scan USB drives for viruses
• Avoid using USB drives on infected computers
• Do not use cheap or counterfeit pen drives
• Avoid leaving USB drives plugged in for long periods

Frequently Asked Questions (FAQ

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Final Thoughts

USB pen drive errors are frustrating, but most are fixable without replacing the drive. Start with basic Windows tools and move to advanced methods only if needed.

If one method doesn’t work, try the next — don’t panic.

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