How to encrypt a USB drive on a Mac with Disk Utility
Disk Utility can lock an external drive with a password, but only by erasing it first, so copy your files off before you start. After that, macOS asks for the password every time the drive is connected. The Finder offers the same lock through a right-click Encrypt command on drives that are already in a supported format.
Apple's Disk Utility guide gives this order:

Disk Utility deletes everything on the stick as part of encryption. Apple puts it plainly: "To encrypt and protect the device with a password using Disk Utility, you must erase the device first." Confirm every file is copied before you click Erase.
Can one password-protected flash drive work on both Windows and Mac?
Not with the built-in tools. BitLocker To Go is a Windows feature and an encrypted APFS volume belongs to macOS, and Proton's guide to USB encryption notes that operating-system encryption will not work across systems. For a shared stick, the realistic choices are an encrypted archive, a VeraCrypt container or a drive with its own keypad.
Keep a shared exFAT stick as exFAT, which Windows and macOS both read and write, and keep the private files secure inside something both systems can open.
How to encrypt a USB drive with a free VeraCrypt container
VeraCrypt is a free, open-source tool that stores an encrypted container file on the stick and mounts it as a drive after you type the password. It suits a stick you plug into your own computers. On someone else's Windows PC it needs administrator rights even in portable mode, because it loads a driver to mount the container.
The VeraCrypt beginner's tutorial names a USB memory stick as one place the container can live:
Dismount the container before you unplug the stick, or the last changes inside it may not be written.
Is a password-protected 7-Zip archive good enough?
For keeping a handful of files away from casual readers, yes. 7-Zip encrypts .7z archives with AES-256, and with file-name encryption turned on, nobody sees the file list without the password. Every machine needs an archiver, and changing one file means extracting it and packing the archive again.
The 7z format page confirms AES-256 support, and 7-Zip itself is free under the LGPL. To build the archive on Windows:
Is a USB flash drive with hardware encryption and a PIN pad worth it?
A keypad drive is the one option that does not depend on the computer. You type a PIN on the drive itself, so it works with Windows, macOS or anything else with a USB port. Kingston's IronKey Keypad 200, for example, is described by the vendor as using XTS-AES 256-bit hardware encryption. The trade-off is trusting claims you cannot check yourself.
According to Help Net Security's coverage of the launch, the Keypad 200 has no factory PIN, so you set your own on first use. At launch it came in capacities from 8 GB to 128 GB with a three-year limited warranty.
Proton's USB encryption guide calls hardware security claims "extremely difficult to verify" and advises buying only from brands you trust. A keypad drive suits machines you cannot control or install software on. For a stick you already own, software encryption costs nothing extra, while hardware encryption means buying a new drive and trusting its security claims.
Which method should you pick?
Choose how to encrypt a USB drive by the computers you will plug the stick into. Windows Pro on every machine means BitLocker To Go. Any Windows Home PC in the chain calls for a tool with its own opener. A Mac in the mix calls for a container, an archive or a keypad drive.
Walk down the list and stop at the first line that matches you:
| Method | Where you can set it up | Opening on another computer | Encryption |
|---|---|---|---|
| BitLocker To Go | Windows 10/11 Pro, Enterprise, Education | Password on other Windows PCs (Home not confirmed by Microsoft) | AES-128 by default, 256-bit optional |
| USB Drive Encryption | Any edition of Windows 10/11 | Opener on the stick, no install, no admin rights | AES-256-GCM, Argon2id key |
| macOS Disk Utility | Mac (erases the drive first) | Password when connected to a Mac | Encrypted APFS or Mac OS Extended |
| VeraCrypt container | Windows, macOS, Linux | VeraCrypt installed, admin rights on Windows | Chosen at setup |
| 7-Zip archive (.7z) | Any PC with 7-Zip | An archiver that reads encrypted 7z | AES-256 |
| Keypad drive (IronKey Keypad 200) | Bought as hardware | PIN on the keypad, any system | XTS-AES 256-bit (vendor claim) |
What happens if you forget the password of an encrypted USB drive?
With real encryption, the password or the recovery key is the only way back in. Microsoft's FAQ says a BitLocker drive cannot be recovered without its password or recovery key, and Apple warns that you cannot open an encrypted disk without its password. Save the recovery key the moment you create it.
BitLocker To Go offers three backup choices in its setup wizard. USB Drive Encryption shows its recovery key once, after you set the master password. In the portable opener, Forgot the password? Use the recovery key switches the password box to the key.
If you change the master password later, drives encrypted earlier keep the password they were encrypted with and still open with the recovery key. When the app says your master password does not open a drive, try the old password.
Lose both the password and the key, and the data is gone. Nobody at our support desk, Microsoft or Apple holds a spare copy. Proton's guide also says no encryption system is foolproof.
Never keep the recovery key on the drive it opens. Print it or keep it in a password manager.
How to remove password protection from a USB stick
Open the drive with its password, then switch encryption off in the same tool that turned it on. BitLocker To Go has a Turn off BitLocker command, USB Drive Encryption has Decrypt, and a Mac drive needs its files copied off before you erase it back to a normal format. Once decrypted, the stick is readable by anyone who holds it.
On Windows Pro, open Control Panel, go to BitLocker Drive Encryption and click Turn off BitLocker next to the stick after typing its password. Leave the stick connected until Windows reports that decryption is finished.
In USB Drive Encryption, click Decrypt next to the stick. Every file returns to its normal form and the protected folder disappears. View files only shows the contents and leaves the drive encrypted. You can encrypt the stick again later; in the free version each new protection counts toward the three runs. On a PC without the app, the portable opener does the same job with Decrypt the whole drive.
For a VeraCrypt container, mount it, copy the files out and delete the container file. For a 7z archive, extract it and delete the archive. On a Mac, copy the files off, then erase the stick in Disk Utility to a non-encrypted format such as exFAT if it also has to work on Windows.
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