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Format Large Drives to FAT32

Step-by-Step Guide: Format Drives Bigger Than 32GB to FAT32

Wilford Conrad |

Have you ever tried to format a 64GB or 128GB drive to FAT32, only to run into problems or find that Windows won't allow it? If you have this problem, you've come to the right place. 

formatlargedrives

Many people encounter a similar problem, and applications such as GUI Format Download are frequently recommended because they easily get over Windows' 32GB limit.

This limitation frequently confuses users, particularly when devices require FAT32 to function correctly. What is the good news? You may format drives greater than 32GB to FAT32 in a safe, simple, and straightforward manner.

In this guide, you'll discover why Windows restricts FAT32, how to get around the limit, and the most trusted tools and methods for completing the procedure without difficulty.

Why FAT32 Is Still Useful Today?

Even though FAT32 is an older file system, it remains widely used because it offers several practical advantages:

1. Universal Compatibility

Almost all devices, including smart TVs, game consoles, routers, cameras, & older PCs, are compatible with FAT32. FAT32 is the safest choice when you need broad compatibility because many devices still don't support NTFS or exFAT. 

2. Lightweight and Efficient

It is ideal for USB devices, SD cards, and other portable storage devices due to its straightforward file format. FAT32 uses fewer system resources and manages routine file operations with ease. 

3. Great for Flash-Based Storage

Fast detection and dependable performance during routine read/write tasks are enabled by FAT32 optimization in many embedded systems & portable devices. 

The only major limitation is the 4GB-per-file limit, but for many devices, it doesn’t cause issues.

Why won’t Windows format Drives Larger Than 32GB to FAT32?

Windows prevents FAT32 formatting above 32GB for a few practical reasons:

  • Promotes Modern File Systems: Microsoft recommends using NTFS or exFAT because they are more feature-rich and better handle large drives than FAT32.

  • Older Structure Isn’t Ideal for Big Drives: FAT32 can support drives up to 2TB, but its architecture grows more slowly and less efficiently as drives get larger.

  • File System Limitations: Windows limits FAT32 to prevent user problems because its 4GB-per-file limit makes it inappropriate for many contemporary workloads.

  • Intentional System Limitation: For disks larger than 32GB, programs like GUI Format are required because Windows prevents massive FAT32 formatting via File Explorer to avoid performance or compatibility issues.

How to Format a Drive Larger Than 32GB to FAT32 (Without Errors)?

Below are the safest, most reliable ways to format USB drives, SD cards, SSDs, and external HDDs to FAT32,  even up to 1TB or more.

Method 1: Format Using PowerShell

Although Windows Explorer blocks FAT32 for larger drives, PowerShell can still perform the task for specific storage sizes. It uses built-in system commands that offer more flexibility than File Explorer.

This makes it a practical option when you want a simple, quick method that doesn't require installing third-party tools.

Steps:

  1. Insert your USB or external drive.
  2. Open PowerShell → Run as administrator.
  3. Enter this command (replace E: with your drive letter):
    format /FS:FAT32 E: /Q
  4. Press Enter and wait.

When to Use This:

  • Works for many drives up to 64GB or sometimes 128GB.
    Quick and built into Windows.

If you get an error, switch to Method 2.

Method 2: Format Using a FAT32 Tool (GUI Format Recommended)

Windows does not support FAT32 formatting for drives larger than 32GB; thus, using a specialized FAT32 application is the most reliable option.

These programs work around Windows' built-in limitations and provide a better, more stable formatting procedure.

They are instrumental when working with larger disks, such as 128GB or 256GB, when command-based solutions frequently fail. This makes third-party utilities a reliable option for achieving error-free results.

Best Tools:

  • GUI Format (FAT32 Format Tool) – simple and highly effective
  • Rufus
  • AOMEI Partition Assistant
  • MiniTool Partition Wizard

Steps (Using GUI Format):

  1. Download GUI Format (portable, no installation required).
  2. Open the tool and select your drive.
  3. Keep the allocation size default.
  4. Click Start → confirm.
  5. Wait for completion.

Why GUI Format Works Best:

  • Supports 64GB, 128GB, 256GB, and larger
  • Fast, stable, and error-free
  • Removes the Windows 32GB restriction

If you want guaranteed success, GUI Format is the safest option.

Method 3: Format Using DiskPart (Advanced Users)

DiskPart can perform FAT32 formatting, but Windows still restricts larger volumes. Useful mainly for custom partitions.

Steps:

  1. Open Command Prompt (Admin).
  2. Type:
    diskpart
    list disk
    Select disk X
    list partition
    Select partition Y
    format fs=fat32 quick
  3. Complete the process.

When to Use:

  • When you need custom partition control
  • For advanced bootable drive preparation

Tips to Avoid Formatting Errors

Use these best practices to prevent issues:

  • Remove write protection: Some USB drives and SD cards have a physical switch. Make sure it’s off before formatting.

  • Close all programs using the drive: Open files or apps can block formatting. Close all programs and background processes to avoid errors.

  • Use a USB 3.0 port: A USB 3.0 port ensures faster transfer and a more stable connection during formatting.

  • Temporarily turn off antivirus: Security software can block formatting commands. Turning off the antivirus temporarily reduces interruptions.

  • Backup your data first: Formatting deletes all data. Always back up important files before starting.

When Should You Use FAT32?

FAT32 is still useful when broad device compatibility is needed. Here’s when it works best:

  • Smart TVs and Media Players: Many TVs and media devices only recognize FAT32 for USB drives, ensuring smooth playback.

  • Gaming Consoles: Older consoles like PS3 and Xbox 360 require FAT32 for storage and updates.

  • Routers and Network Storage: Some routers only support FAT32 for USB-attached storage.

  • Cameras and Portable Devices: Many cameras and drones rely on FAT32 to reliably store photos and media.

Note: Avoid FAT32 if you need to store files larger than 4GB; use exFAT instead.

Final Thoughts

Formatting disks greater than 32GB to FAT32 is not difficult; Windows makes it appear that way. You can get around the 32GB limit by using tools like GUI Format, PowerShell, or DiskPart to format your drive quickly and safely.

Whether you're prepping storage for a console, TV, or router, these approaches ensure seamless compatibility and flawless formatting.

Taking the necessary measures and using reliable tools ensures your drive remains solid and functional for many years to come.

About the Author:

I'm Wilford Conrad, a web developer who enjoys breaking down complex technological jobs into simple, actionable guidelines.

I specialize in storage solutions, resolving drive issues, and assisting users with technical tasks without frustration.

My guide will help everyone grasp complex processes and avoid errors. 

Ref:

Glenn, W. (2023, October 17). How to format USB drives larger than 32GB with FAT32 on Windows. How-To Geek. https://www.howtogeek.com/316977/how-to-format-usb-drives-larger-than-32gb-with-fat32-on-windows/

 

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