USB stick became unusable

Wintoflash Support team

Try WinToFlash Erase option in Advanced mode. 

If it won't work (or WinToFlash will not be able to Erase the drive) 

use  WinHEX:  open the media (your USB drive)

Tools - open disk - Edit - Fill disk sectors

Fill first ~1000 sectors with 0, replug the USB and try to format it again with Windows.

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Overview to WinToFlash.
Quickly and simply install the program you needs and in no time at all you will find yourself writing essays on Windows and using your USB. The WinToFlash makes the job hassle free for you.

WinToFlash is software for transfer your Windows XP, Windows 2003, Windows Vista, Windows 2008, Windows 7, Windows 8 Setup from CD or DVD to USB in some mouse clicks. This is about you can install your Windows from flash drive or card, HDD, etc. to your computer or netbook.
And this is not all it can do. WinToFlash can transfer your live CD or DVD to USB card, for example, BartPE. After all you can erase your USB media and format it with Windows for everyday use.
gnrsu.com/wintoflash.html

WinToFlash is a software for transfer your Windows XP, Windows 2003, Windows Vista, Windows 2008, Windows 7 setup from CD or DVD to USB in some mouse clicks. This is about you can install your Windows from flash drive, USB pen, HDD, etc to your computer or netbook.
And this is not all it can do. WinToFlash can transfer your live CD or DVD to USB card, for example, BartPE. After all you can erase your USB media and format it with Windows for every day use.

[ Key Features ]

• Windows XP/2003/Vista/2008/7 to USB transfer
• WinPE to USB transfer
• USB media erasing, full of quick
• Create the USB drive with emergency boot loader
• DOS to USB transfer

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WinHex is in its core a universal hexadecimal editor, particularly helpful in the realm of computer forensics, data recovery, low-level data processing, and IT security. An advanced tool for everyday and emergency use: inspect and edit all kinds of files, recover deleted files or lost data from hard drives with corrupt file systems or from digital camera cards. Features include, depending on the license type (comparison):

• Disk editor for hard disks, floppy disks, CD-ROM & DVD, ZIP, Smart Media, Compact Flash, ...
• Native support for FAT12/16/32, exFAT, NTFS, Ext2/3/4, Next3®, CDFS, UDF
• Built-in interpretation of RAID systems and dynamic disks
• Various data recovery techniques
• RAM editor, providing access to physical RAM and other processes' virtual memory
• Data interpreter, knowing 20 data types
• Editing data structures using templates (e.g. to repair partition table/boot sector)
• Concatenating and splitting files, unifying and dividing odd and even bytes/words
• Analyzing and comparing files
• Particularly flexible search and replace functions
• Disk cloning (under DOS with X-Ways Replica)
• Drive images & backups (optionally compressed or split into 650 MB archives)
• Programming interface (API) and scripting
• 256-bit AES encryption, checksums, CRC32, hashes (MD5, SHA-1, ...)
• Erase (wipe) confidential files securely, hard drive cleansing to protect your privacy
• Import all clipboard formats, incl. ASCII hex values
• Convert between binary, hex ASCII, Intel Hex, and Motorola S
• Character sets: ANSI ASCII, IBM ASCII, EBCDIC, (Unicode)
• Instant window switching. Printing. Random-number generator.
• Supports files >4 GB. Very fast. Easy to use. Extensive online help. (more)

Having all the bits and bytes in a computer at your fingertips has become a reality. Try before you buy, as long as you need, for free.