Unable to Duplicate MicroSD for Booting OrangePi Zero3

Hello,
I tried to duplicate an existing - and working - micro sdx card containing a bootable dietpi partition to another one with less physical space on it.

I did resize the root partition so that it easily fits on the new sd card. Afterwards I did a copy using dd like this:

dd if=/dev/sdb1 of=/dev/sdc1 bs=1M

The duplication process seemed to work flawlessly. Structure of both SD cards look identical to me (msdos partition table, 4MB unallocated space in the beginning, then the root partition)

When I try to boot from the new SD card, I get some error “Failed to mount /dev/mtdblock4”

Any ideas about this?

Thanks and regards

Hello
You are under Windows or Linux ?

I copy my sd card with Disk and
I use a command line to reduce size with gparted and troncate but under Linux ubuntu

I am using Ubuntu for the SD card management. I’ll Try later on with a different “brand” card to exclude the possibility of bad hardware. Just wanted to know, if someone had similar occurences and / or if this is a known problem with the OrangePi series (e.g. a specific layout on SD card could be needed).

Now I’m finally clear, this is NOT a bad hardware problem. Happened with another card of the same brand as the original one: both are SanDisk Extreme Pro 64GB.

After issuing the error message given in the original post the device reboots - and ends up in the same error (boot loop)
What exactly could be the reason for this behaviour?

Where in the boot process is that /dev/mtdblock4 mentioned? What is the device referring to?

I use an OPI zero 2w , it’s similar but
It’s /dev/mmcblk0p1 not /dev/mtdblock4 in my memory
I can veridied tonight at home
It refer to the partition on the SD card

user@user:\~# lsblk
NAME        MAJ:MIN RM   SIZE RO TYPE MOUNTPOINTS
sda           8:0    0 931.5G  0 disk
└─sda1        8:1    0 931.5G  0 part /mnt/Nextcloud02
sdb           8:16   0 931.5G  0 disk
└─sdb1        8:17   0 931.5G  0 part /mnt/Nextcloud01
mtdblock0    31:0    0    16M  0 disk
mmcblk1     179:0    0 119.1G  0 disk
└─mmcblk1p1 179:1    0 119.1G  0 part /

I think you need to copy the whole disk, and not just the partition. The bootloader for this board should be at the beginning of the card in the “raw space”.

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Arrafar and Jappe confirm
You need to copy the whole SD card
The capture of the SD card on my laptop
Capture d’écran du 2025-09-01 23-12-42
And the same SD card view with “lsblk” in the ssh connection

Hope it help

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Ok, this makes absolutely sense to me - I did not know, that this is the way the boot sequence is working.

So I tried once again and just cloned the whole disk - ignoring the different physical sizes -

It worked!

I expected to get some error saying, that the process cannot write any more blocks on the target disk, because that one is smaller than the source. - Excatly that happened, but did not have any consequences regarding the usability of the resulting copy.

Thank you all for your input to this general topic!!

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