It happened to me also you simply need to paste this commands in your Terminal, these commands ignores these errors and formats the Disks successfully no need to go to Disk Utility these commands will also create the bootable drive
Note: These commands are for macOS Sierra/High Sierra do the changes as per your needs! (This also works for any Previous version of macOS)
First you would need to download macOS Sierra Installer(Whichever OS you want),
Then you would have to make a bootable disk containing the Install macOS Sierra.app (Whichever OS you want)
I am also providing you a link to a YouTube video which will help you in creating the bootable USB stick link: https://www.youtube.com/watch?v=v4H5hKuI7yg&t=130s
I am also adding the command required to create the bootable disk:
sudo (path to the create install media file under installer.app>Contents>Resources) --volume {path to the USB stick (You are trying to make bootable)} —applicationpath (path to your Install macOS sierra.app)
e.g:
sudo /Applications/Install\ macOS\ Sierra.app/Contents/Resources/createinstallmedia --volume /Volumes/MyVolume --applicationpath /Applications/Install\ macOS\ Sierra.app
Please make the necessary changes as per your files and volumes
The maximum allocation block (or cluster) count for exFAT is 2^32 = 4,294,967,296.
To get the minimal size of an allocation cluster on your partition divide the size of your partition through 2^32.
Examples:
for a 100 GB partition the minimal size is 100,000,000,000 bytes/4,294,967,296=~23.3 bytes. Since the smallest device block size is 512 bytes, the allocation block size can't be smaller.
For a 3 TB partition the minimal size is 3,000,000,000,000 bytes/4,294,967,296=~698.5 bytes. The minimal possible allocation block size is then 1024 bytes.
To format a partition use newfs_exfat [options] /dev/disk*s*
The following options regarding allocation block sizes are available:
-b bytes-per-cluster
File system block size (bytes per cluster). Acceptable values
are powers of 2 in the range 512 through 33554432.
-c sectors-per-cluster
Sectors per cluster. Acceptable values are powers of 2 in the
range 1 through 65536.
To reformat your exFAT volume first copy the content to another volume. Then enter:
diskutil list #to get the disk identifier of the exFAT partition
diskutil unmount /dev/disk0s6
sudo newfs_exfat -c 1 -v exFAT /dev/disk0s6
diskutil mount /dev/disk0s6
The command will create one allocation (or cluster) block/device block and rename the volume to exFAT.
Alternatively you may use
sudo newfs_exfat -b 512 -v exFAT /dev/disk0s6
Most modern HDDs or SSDs use device block sizes of 4096 bytes and the displayed device block size of 512 bytes is only a "logical" device block size probably for compatibility reasons. So a minimal allocation block size of at least 4096 bytes is recommended.
Also the default cluster block sizes of various sized exFAT partitions in Windows "mention" at least 4 kb.
To get the current cluster block size (and other informations) of an exFAT volume do the following:
diskutil list #to get the disk identifier of the exFAT partition
diskutil unmount /dev/disk0s6
sudo newfs_exfat -N /dev/disk0s6
diskutil mount /dev/disk0s6
Best Answer
I don’t know a good way to test disks for sizing without a third party program or command line tools.
The former, I use SD Clone: https://twocanoes.com/knowledge-base/sd-clone-3-getting-started/
The latter - try these commands once you get the unix disk number from Disk Utility or another means - be 100% sure you have a backup of every single drive connected. If you get the drive number wrong (in the linked question the USB drive to be erased is disk3 and those numbers can change each time you eject and mount a drive), you will erase without a chance of recovery whichever drive you perform this on:
When I say “be sure of your backup”, that you have set aside the time and steps needed to restore that backup - not just “maybe it’s current and I haven’t checked it for a while” type backup. Hopefully it’s a quick erase and not that the disk itself is broken or mislabeled.