How to create a bootable ESXi USB disk on macOS
Insert USB drive in your computer. Open Terminal and list the mounted disks using the following command (note disk#):
$ diskutil list
Now we will format the disk using FAT32 filesystem and MBR partition map
$ diskutil eraseDisk MS-DOS "ESXI" MBR disk#
Unmount the USB drive:
$ diskutil unmountDisk /dev/disk#
Next we need to flag the first partition as bootable:
$ sudo fdisk -e /dev/disk# f 1 w q
Mount the ESXi ISO image and copy all the files to the USB drive.
Locate the file ISOLINUX.CFG on the USB drive and rename it to SYSLINUX.CFG
mv /Volumes/ESXI/ISOLINUX.CFG /Volumes/ESXI/SYSLINUX.CFG
Open the SYSLINUX.CFG file and append the bold characters to the existing line:
APPEND -c boot.cfg -p 1
Save and close the file, and eject the USB drive. Now you can boot from the USB drive.
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