Failed to Create Recovery Media! Error Code=63

Scenario

Failed to create the rescue media on a USB stick - the process stops in the middle with Error code 63

Possible root causes

• The volume has errors or bad blocks.
• Some configuration or .dll files in program directory are corrupted or missing.
• Program files, folders or system resources are blocked.
• Device file system is locked by another process and can’t be handled.

Solution

• Make sure USB drive has write protection hardware lock turned off.
• 3rd party is conflicting with our engine when our code tries to write to drive - make sure no files/handles are still opened on the drive (100% way is to delete all volumes on USB drive in Windows Disk Management and force dismount if WDM asks for it). If it doesn't help, then disable antivirus and other similar system software.
• USB drive I/O failures caused by disk faults - try other USB drive
• If nothing helps and you are sure about USB drive health, full initialization should help:
  1. Please open CMD with admin rights
  2. Start Diskpart with the following command: diskpart
  3. List the disks so that you can see which one is the USB stick: list disk
  4. Now use the command to select the USB stick (>< = placeholder): select disk >number of the USB stick<
  5. Once the stick is selected, please execute the following commands ONE AFTER THE OTHER: clean convert mbr exit