Why FAT32 still matters for large USB drives
Many devices still expect FAT32. Cameras, smart TVs, car stereos, legacy game consoles, and some firmware updaters read FAT32 more reliably than NTFS or exFAT. The challenge appears when Windows tools do not show FAT32 for drives larger than 32 GB, which leads users to think it is impossible.
Quick answer, how to format over 32 GB to FAT32 on Windows
Use a dedicated formatter. Create one primary partition, choose FAT32, pick a sensible cluster size, then format. Afterward, verify the file system and capacity in Properties. If the drive will hold a Windows installer, create the bootable media after formatting.
FAT32 limits to know, partition size, file size, and compatibility
FAT32 supports large volumes in practice, but it has a strict file size limit of 4 GB minus 1 byte per file. This matters for installers, disk images, and videos. For a concise comparison across file systems, see Microsoft’s official overview of file system capabilities in File System Functionality Comparison on Microsoft Learn, which lists limits and features for NTFS, exFAT, UDF, and FAT32. https://learn.microsoft.com/en-us/windows/win32/fileio/filesystem-functionality-comparison
Why Windows shows a 32 GB cap in the default tools
On many Windows builds, the graphical Format dialog and Disk Management only present FAT32 for small drives. The cap is a design choice in the built-in tools. It does not mean the drive cannot use FAT32. Third party utilities and some command line paths can format larger volumes.
Preparation and safety, backups, correct drive selection, and errors to avoid
- Back up any needed files first. Formatting erases data.
- Confirm the correct drive letter. Unplug other removable disks to prevent mistakes.
- Prefer USB ports on the motherboard instead of a hub during formatting.
- Close programs that might be accessing the drive to avoid a “volume in use” error.
Method 1, format to FAT32 with GUIFormat, step by step
Download and checks
Obtain a trusted copy of the FAT32 GUI formatter. Save it locally, then open it with administrative rights if prompted.
Recommended settings and cluster size
- Drive, pick the correct letter for the USB flash drive.
- Allocation unit size (cluster size), start with 32 KB for 64 GB to 256 GB sticks. For very large USB drives, 64 KB can reduce fragmentation at the cost of slightly larger overhead for many tiny files.
- Volume label, add a short name, for example “FAT32USB”.
- Quick Format, enabled for a fast reformat. Disable it only when checking a suspect drive.
Run and verify the result
Select Start. When complete, open This PC, right click the drive, choose Properties, and confirm File system: FAT32 and the expected capacity.
Method 2, format with command line alternatives, what works and what fails
Where Format and DiskPart succeed or stop
On some systems, the format command or diskpart will create large FAT32 volumes. On others, these tools still refuse sizes above 32 GB. If an error mentions volume size, return to Method 1.
When to use third party tools instead
Use the dedicated FAT32 formatter if the Windows tools hide FAT32 or abort mid-process. This is the common path for 64 GB and larger sticks that must remain FAT32 for device compatibility.
Create bootable media after formatting, when to bring in Rufus
After a successful FAT32 format, create the installer. A clear walkthrough is available here, how to install Windows 10 or 11 from USB using Rufus, which explains selecting the ISO, partition scheme, and target system, then writing the image in a reliable way. https://byalexdavid.com/how-to-install-windows-10-or-11-from-usb-using-rufus
Troubleshooting, common errors and how to fix them
- FAT32 not shown, use the dedicated formatter or try the command line on newer Windows builds.
- Windows cannot complete the format, safely eject, reinsert, and retry Quick Format. If it persists, run chkdsk /f on the drive, then format again.
- Drive reports the wrong size, open Disk Management, delete all partitions on the USB, create one Primary partition, then format to FAT32.
- Single file larger than 4 GB will not copy, split the file, compress it, or use exFAT or NTFS instead.
When to choose exFAT or NTFS instead
Choose exFAT when files exceed 4 GB and cross platform use is important. Choose NTFS for Windows only use, permissions, and reliability features. Keep FAT32 for devices that demand it, for example some BIOS update tools, media players, or legacy consoles.
Conclusion
FAT32 still solves real compatibility problems across devices. The 32 GB limit seen in many Windows tools is a software choice, not a universal barrier. Format with a dedicated FAT32 utility, verify the result, then create the installer with Rufus if needed. For ongoing use, remember the 4 GB per file limit and switch to exFAT or NTFS when large files are required.