Creating a Windows 10 Install USB when FAT32 has 4GB max file size So I am attempting to create a Windows 10 install USB on my MBP running macOS 10.14 Mojave. To create a bootable USB it needs to be formatted into FAT32, not exFAT. The issue is that when copying the .iso to the USB it fails because the file sources/install.wim is 4.4GB. I can't format as exFAT because I cannot boot from that format and I cannot use FAT32 because of the 4.4GB file. I used the command cp -rpv /Volumes/CCCOMA_X64FRE_EN-US_DV9/* /Volumes/WINDOWS10/ after Boot Camp Assistant failed to create the  USB with a "Drive too small" error, even though it was a 16GB drive. When I wasn't paying attention, the cp completed and the installer booted, but failed with a missing: sources/install.wim error because the file can't be copied.

Is there any solution to this problem, or should I just burn a DVD with the installer on it?

EDIT: I forgot to specify that I was creating a USB for a PC, not a Mac. The Mac was just being used to create an install USB.

Heres the file:
The only way I was able to successfully overcome this problem was following this person's guide:


  The final problem is that the install.wim file is too big to copy across to the FAT32-formatted USB stick (you can try, but will be met with an error). On Windows, Microsoft's official solution is to split the file using a special tool designed for these .wim files. Fortunately, there's also a free alternative called wimlib which works on Mac (and Linux).


With wimlib installed, available via Homebrew (brew install wimlib), you can easily perform the file splitting of install.wim that the Windows 10 ISO will automatically pickup and understand with no extra fuss.

wimlib-imagex split /Volumes/CCCOMA_X64FRE_EN-US_DV9/sources/install.wim /Volumes/WINDOWS10/sources/install.swm 4000