How to Install Windows 10 from USB on a New PC

Jean updated on Mar 16, 2020 to Partition Manager | How-to Articles

If your personal data is lost, deleted, or hidden due to Windows 10 KB4540673 update, download EaseUS Data Recovery Wizard to find the missing files.

If you're looking for a simple tutorial on how to install Windows 10 on a new PC only with the help of a USB flash drive, don't walk away.

Take two minutes to read through this page. As estimated, 90% of the readers would be able to start alone to install Windows 10 from USB on their new PCs in the end. Now, it's your time.

Things you need to prepare in advance

  • Windows 10 install.iso file or DVD
  • A USB flash drive with at least 5GB free space.
  • An idle computer where you'll format the USB flash drive.
  • EaseUS Partition Master - The best USB format tool.
  • Your new PC - which you'll install Windows 10 on it.

Three steps for installing Windows 10 from USB on a new PC

Step 1. Format the USB drive and set the primary partition as active

Click the download button and install EaseUS Partition Master Free on the idle computer, which can be your old one or your friend's.

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 Windows 10 is supported

Connect the USB flash drive to the computer. 

Open EaseUS Partition Master Free.

Format the partition: Right-click the USB drive partition and choose Format partition. Select the FAT32 file system from the drop-down file system list (FAT32 is the optimal file system. It's able to boot either BIOS-based or UEFI-based PCs). Click Apply to save the changes.

format usb flash drive with fat32 file system to install windows 10 from it

Set the partition as active: Right-click the USB drive partition and choose Set active. Click Apply to save the changes.

set usb drive partition as active to install windows 10 from it

The Set active option is only available when your USB flash drive partition style is Primary. You might need to convert the logical partition to primary partition if marking the partition as active fails at this step.

Step 2. Copy Windows Setup to the USB flash drive

Use File Explorer to copy and paste the entire contents of the Windows product DVD or ISO to the USB flash drive.

Tips and tricks
Due to the limitation of the FAT32  file system, you will not be able to copy the file larger than 4GB to FAT32 USB flash drive, but the Windows 10 image file happens to exceed the FAT32 file size limit of 4GB. You can troubleshoot the file copy failure like this.

1. Copy everything except the Windows image file (sources\install.wim) to the USB drive using this command, where D: is the mounted ISO and E: is the USB flash drive.)

robocopy D: E: /s /max:3800000000

2. Split the Windows image file into smaller files, and put the smaller files onto the USB drive:

Dism /Split-Image /ImageFile:D:\sources\install.wim /SWMFile:E:\sources\install.swm /FileSize:3800

Step 3. Install Windows 10 from the USB flash drive on your new PC

Connect the USB flash drive to a new PC.

Turn on the PC and press the key that opens the boot-device selection menu for the computer, such as the Esc/F10/F12 keys. Select the option that boots the PC from the USB flash drive.

Windows Setup starts. Follow the instructions to install Windows 10.

Remove the USB flash drive.

Sometimes, it'll be greater to install Windows 10 on an external hard drive. By this way, you can use your own customized Windows 10 operating system wherever you go.


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Will it cause any data loss after resizing the partition in EaseUS Partition Master?

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