[mothered]

The native Windows format utility, Is pretty mediocre. Have you tried a LLF (Low Level Format) on the SD Card?

This type of formatting, bypasses the file system layer of the disk, and formats directly against the underlying storage of the device. There's heaps of tools that do the job, and here's just one of them. It's free for personal use (with some restrictions), but nonetheless, gets the job done. SD Cards are supported.

Link: http://hddguru.com/software/HDD-LLF-Low-...rmat-Tool/