Unable to create a bootable USB stick

Disk Drill for Mac and Windows – Help Center Forums General Unable to create a bootable USB stick

This topic contains 3 replies, has 2 voices, and was last updated by  OS2Nutcase 8 months, 4 weeks ago.

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    I am wondering if anyone else is having issues creating a bootable usb stick using Disk Drill 3.1.817 Pro and Mac Sierra (10.12.5)

    I have tried an SD card and several different USB keys including pulling my ESXi USB boot key and I keep getting the same following error code.

    Disk Drill failed creating bootable disk with error: Can’t mount device disk0s3 to path /var/folders/8v/wx9v80bd2fb7lswq307c1gh40000gn/T/btdkgGsAKfeV/r. Process exited with nonzero status 1 – please try to reattach the destination drive and/or reboot your computer.

    I have rebooted my MacBook Pro several time as well and this is stumping me.I am using a USB known to be bootable and when I click make bootable I get an error.

    Is there another way to create the boot key?

    System Details:

    Model Name: MacBook Pro
    Model Identifier: MacBookPro11,5
    Processor Name: Intel Core i7
    Processor Speed: 2.5 GHz
    Number of Processors: 1
    Total Number of Cores: 4
    L2 Cache (per Core): 256 KB
    L3 Cache: 6 MB
    Memory: 16 GB
    Boot ROM Version: MBP114.0172.B16
    SMC Version (system): 2.30f2

    Physical Volumes:
    Device Name: APPLE SSD SM0512G
    Media Name: APPLE SSD SM0512G Media
    Size: 499.42 GB (499,418,034,176 bytes)
    Medium Type: SSD
    Protocol: PCI
    Internal: Yes
    Partition Map Type: GPT (GUID Partition Table)
    Status: Online
    S.M.A.R.T. Status: Verified

    USB 2.0 FD:

    Product ID: 0x007a
    Vendor ID: 0x154b (PNY Technologies Inc.)
    Version: 11.00
    Serial Number: B1311070000107
    Speed: Up to 480 Mb/sec
    Manufacturer: PNY Technologies
    Location ID: 0x14200000 / 8
    Current Available (mA): 500
    Current Required (mA): 500
    Extra Operating Current (mA): 0
    USB 2.0 FD:
    Capacity: 16.25 GB (16,252,928,000 bytes)
    Removable Media: Yes
    BSD Name: disk2
    Logical Unit: 0
    Partition Map Type: GPT (GUID Partition Table)
    USB Interface: 0
    Capacity: 4.2 MB (4,161,536 bytes)
    File System: MS-DOS FAT16
    BSD Name: disk2s1
    Content: EFI


    Unfortunately, we are confirming this with the latest macOS. A lot has been silently changed by Apple in Recovery HD which is the basis for boot drives created. We are actively looking into this issue.


    Please check out the newest release, Disk Drill 3.2 (macOS). The issue with the boot drive creation has been fixed: http://www.cleverfiles.com/getdiskdrill



    Haven’t had a chance to update the thread. Thanks for putting the fix out there so quick. I downloaded the update and was able to create the bootable USB stick. 🙂

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