For some reason, DiskUtility in UI might not be able to format USB drive successfully, as an alternatively, CLI could solve the issue.
2. From this list, go ahead and select the device that you want to format and use the Terminal to format it.
Use the following syntax to format the drive:
diskutil erasedisk FILE_SYSTEM DISK_NAME DISK_IDENTIFIER
3. For the Disk name, you can enter any name you want to give your device.
To find your Disk identifier, refer to…