Error 23 - "an error occurred when attempting to write data from handle"

This one is particularly troubling. It indicates corruption on the filesystem (according to several google search results). But which filesystem? Is it where the image file is located or is it the flash device? Unfortunately, there is not an easy generic answer to this.

The first possibility is that the image file you are trying to write is itself corrupted. This can be checked by checking the MD5 checkbox and comparing the generated hash with a hash from the download source for that image.

Based on various internet results, there is a possibility that the OS drive has a bad sector where the image file is stored. It is recommended that the user runs a full disk scan on their OS drive. The best way to do this is to open a command shell (Start->Run cmd <enter>) and then type "chkdsk c: /r /f". It will prompt indicating that this is not safe to run during normal operations and ask if you want to run it on next boot. Answer "Y" then reboot your system and let it run.

If the fault is not on the OS Drive, then there is a high probability that Windows is trying to do something stupid to the memory device while we are writing a new image (i.e. attempting to index the new disk layout as it is being written). To test this, try using the HP USB Formatter utility on your memory device. If that succeeds, try reading your memory device to a test.img (in v0.7, just type "test.img" in the file text window, it will automatically store it in your Downloads directory). If this passes, try rewriting your img file to the device.

I'm sure there are other reasons for this, but this is the best I have been able to find. If you find a better solution or even a way to reproduce this easily, drop me a note.