So I was all ready to start loading up a server with Windows Server 2012 R2. I had the ISO downloaded, brand new 8GB Kingston USB memory stick and an HP DL360p Gen8. Should be easy right. I downloaded Microsoft’s Windows 7 USB/DVD download tool and proceeded to create a bootable memory stick. Except that the utility did not work. It kept spitting out the error message “We were unable to copy your files. Please check your USB device and selected ISO file and try again” . After trying it over and over again a few times with moving the ISO around and running the utility elevated, nothing worked. I figured it had to be the USB memory stick. For whatever reason, performing a format on a new USB stick just wasn’t enough. I recalled a scenario which I won’t get into now but where SCCM wouldn’t push an OS image onto a machine. My resolution there was to clean the volume, re-create the partition and retry.
With that said, here is what I did to resolve the Windows 7 USB/DBD utility error.
I loaded myself into an elevated command prompt and typed in diskpart to enter the utility and typed the following commands
list disk (Here you want to determine which volume is your USB memory stick)
select disk 1 (Your number may be different. Be sure you are selecting your USB memory stick)
clean (Clean your volume)
create partition primary (Create a new partition)
select partition 1 (Select your new partition)
active (Set the partition as active)
format quick fs=ntfs (Format your new partition, although I did ntfs, the Windows utility will reformat the drive anyways)
assign (you could get fancy here and specify a drive letter. Just typing assign will assign the memory stick the next letter in the sequence)
exit (exit diskpart)
exit (exit command prompt)
From her, just rerun the Windows 7 USB/DVD download tool and your copy should be a success this time. I hope this was helpful for you!