How to deal with the error "Windows was unable to complete the format"?

Contact the manufacturer and start screaming.

This problem or quite similar one was resolved at the following link:

http://ccm.net/forum/affich-5078-windows-was-unable-to-complete-the-format

what operation have you done to the drive before you try to format it? It seems that the drive is damaged. now, you can try Disk Management or Command Prompt to complete the formatting.:
1. Go to Disk Management.( Right-click My Computer>Manage)
2. Right click the drive and select New Simple Volume. Then follow the wizard.
3. The the drive will be formatted.
Method two:
1. click Start button> type cmd in the search both and press Enter
2. Type diskpart on the black windows and press Enter key
3. Continue typing disk 4. Type create primary partition and hit Enter
4. type in Command Prompt format /FS:FAT32J
For detailed steps with picture you need to go http://www.eassos.com/how-to/windows-was-unable-to-complete-the-format.php