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Maybe also try a different USB port if some on the mobo are USB2 and other USB3
The laptop doesn't have any USB A ports, only C so I am using either a USB dock which has only USB 3 ports on or else a little Samsung c to a adapter.
I've tried all the options I have and not noticed a difference. The only thing I haven't tried is a different usb stick. I could try the other identical one I have only I don't have a windows machine to burn it on now.
Is it worth buying a stick with windows already on from eBay or something?
It won't be a problem with it being FAT32 - I have a working Win11 USB that's formatted as FAT32. Think I've used exFAT too without a problem. I definitely remember having issues with a USB drive a few years ago (Win10 days) but can't remember the brand. The two that I have which are both working are a 32GB Samsung 'Flash Drive FIT', and a random unbranded 16GB one that came with the motherboard that originally had the drivers on it (though I guess that at least meant it was likely to be compatible with the board)
Maybe also try a different USB port if some on the mobo are USB2 and other USB3