The USB drive must be empty when you download. Was that the case? Format the whole drive prior to download.
Also the BIos must be set to boot from a removable source, or however it’s worded.
Thanks.yes to all. Many other flash drives boot fine like acronis recovery. Is it possible the program doesn't like partitioned drives? You can't format a 256gb drive as fat32 so that's why I split it into 2 partitions... 1 as fat32 and the large one as either expat or ntfs.