Create bootable USB w. Windows 11 incl. Autopilot JSON file

This guide will go through all steps to create a bootable USB with Windows 11 – that includes the Autopilot profile for your Microsoft Endpoint Manager tenant.

This USB can be used to onboard all computer – just after reinstall.

First you need Windows 11 ISO image – DOWNLOAD

Then you have to download the Autopilot profile to a JSON file.

Open Powershell as Administrator – and download these modules:

Install-Module AzureAD -Force
Install-Module WindowsAutopilotIntune -Force
Install-Module Microsoft.Graph.Intune -Force 
Connect-MSGraph #Connect with your Intune Administrator

Now download your Autopilot profile as JSON

$AutopilotProfiles = Get-AutopilotProfile

Foreach ($AutopilotProfile in $AutopilotProfiles) {

    $TempPath = "C:\DATA\AutopilotProfiles\"

    if (!(Test-Path $TempPath)) {
        New-Item -Path $TempPath -ItemType Directory -Force

    $name = $AutopilotProfile.displayName
    $ExportPath = $TempPath + $name + "_AutopilotConfigurationFile.json"
    $AutopilotProfile | ConvertTo-AutopilotConfigurationJSON | Out-File $ExportPath -Encoding ASCII


Following Autopilot profiles is now downloaded as JSON:

Rename the file you will use to: AutopilotConfigurationFile.json
Save the file for later use in this guide.

Now we will shrink the ISO and inject the JSON file.

We will shrink the image – so we only have Win 11 Pro on the USB.
To know what Index we will export – run this DISM command.
Point to the Install.WIM file under %ISOIMAGE%\Sources\Install.wim

Dism /get-wiminfo /wimfile:"E:\sources\install.wim"

To export Index : 6 – run following DISM command

Dism /export-image /SourceImageFile:"E:\sources\install.wim" /SourceIndex:6 /DestinationImageFile:C:\DATA\WIM\install.wim /Compress:max /CheckIntegrity

Image should now be 500mb smaller – you can run get-wiminfo command again on the new WIM file to verify index.

The new WIM file need to be mounted – so we can inject the JSON file.
Run this command to mount the WIM:

Dism /mount-wim /wimfile:"C:\DATA\WIM\install.wim" /index:1 /mountdir:C:\DATA\Mount 

After WIM is mounted – Copy AutopilotConfigurationFile.json to:

Now Commit the image:

Dism /Commit-Image /MountDir:C:\DATA\Mount 

After Commit – Unmount image:

Dism /Unmount-Image /MountDir:C:\DATA\Mount /commit 

Before we will prepare the USB – we need to split the WIM file.
This is needed as the WIM is larger then 4GB.
Otherwise it can not be saved on a FAT32 USB

Dism /Split-Image /ImageFile:"C:\DATA\WIM\install.wim" /SWMFile:"C:\DATA\SWM\install.SWM" /FileSize:3800 

Now we need to prepare the USB.
Remember USB size: minimum 8GB – maximum 32GB
Insert USB.

Open Command prompt as Administrator

Type: Diskpart

Type: List disk

Select Disk 1 – which is the USB stick
Type: sel disk 1

Type: clean

Create new partition
Type: create part pri

Select new partition
Type: sel part 1

Format the USB stick
Type: format fs=fat32 quick

Type: active

Copy all files from downloaded Windows 11 ISO to USB
Except Install.wim – Instead Install.SWM and Install2.SWM

Now reinstall your PC with the USB – and you will see it attach directly to your MEM Tenant.

Hope you could use the guide!

5 thoughts on “Create bootable USB w. Windows 11 incl. Autopilot JSON file

  1. In case someone run into issues you may have to import the modules after installing them before downloading JSON

    Import-Module AzureAD
    Import-Module Microsoft.Graph.Intune
    Import-Module WindowsAutopilotIntune

    Second DISM was failing to /commit I used /discard
    Dism /Unmount-Image /MountDir:C:\DATA\Mount /discard

    I will test the reinstall tomorrow and report.

    Thank you for this, fingers crossed!

  2. I am getting “We couldn’t find any drives”. This is DELL Vostro with Windows 11 already on it.

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