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Warn about ExFAT boot limitations in Make2023BootableMedia - #482

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Brandon Allsop (ballsop) wants to merge 1 commit into
microsoft:mainfrom
ballsop:fix-424-exfat-boot-warning
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Brandon Allsop (ballsop) wants to merge 1 commit into
microsoft:mainfrom
ballsop:fix-424-exfat-boot-warning

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Description

Fixes #424.

Warn before erasing USB media when ExFAT is selected, explaining its limited UEFI boot compatibility. Retain ExFAT for compatible firmware, but replace the oversized-FAT32 guidance suggesting ExFAT with a recommendation to use a partition of 32GB or smaller.

Update the script version and startup banner to 1.6, dated 2026-10-27.

For details on how to complete these options and their meaning refer to CONTRIBUTING.md.

  • Impacts functionality?
  • Impacts security?
  • Breaking change?
  • Includes tests?
  • Includes documentation?

How This Was Tested

Targeted Pester regression tests cover ExFAT warning ordering and case-insensitive selection, FAT32/default acceptance at 32GB, and FAT32/default rejection at 33GB without suggesting ExFAT.

  • All regression cases passed under both Windows PowerShell 5.1 and PowerShell 7.

Full media creation validation

  • All integration scenarios passed in the USB-path target. Coverage included warning order, cancellation, oversized FAT32 rejection, successful ExFAT/FAT32 creation, and default filesystem behavior.
  • Successful media was checked for the expected filesystem, boot-binary hashes, and FAT32 installation-image splitting. Cancellation and rejection preserved existing test data.
  • Actual firmware boot and physical USB hardware were not tested.

Integration Instructions

N/A

Warn before USB erase confirmation while retaining ExFAT for compatible firmware. Replace misleading oversized-FAT32 advice with guidance to use a partition of 32GB or smaller. Set the script metadata and startup banner to version 1.6, dated 2026-10-27.

Fixes microsoft#424.

Co-authored-by: Copilot <223556219+Copilot@users.noreply.github.com>
Copilot-Session: d646aef3-e25b-46f8-8979-f7165880730a
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[Bug]: exfat option in Make2023BootableMedia.ps1 results in non-bootable USB

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