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Thank you so much! My email is out and I am very appreciative! I plan to hook my prize up to a SmartTV with a wireless mouse/keyboard maybe. I may do some stress testing too, we will see
The error often happens to flash drive such as SD card, USB flash drive, etc. In some case, it's hard to fix or repair the drive, as it might have been damaged. But sometimes you can complete the formatting thing following steps here:
Solution one: recreate the partition for the card with Disk Management which has a simple wizard to finish this.
Solution two: use command line which has been mentioned by others too. Command Prompt is very useful to handle such problem.
Solution three: try the third solution when the first two ways do not work. there are tool to check and repair bad sectors for hard drive or USB drive. you can try one or two to repair the drive. but you should note that bad sector repairing damages data on the drive.
Actually, the "Windows was unable to complete the format" error happened to me once, and the second solution worked on my case. hope that can help you too.