Cluster Size in NT5 up (Windows 2000+) - Use Best Fit

Cluster Size in NT5 up (Windows 2000+) - Use Best Fit

Note: Aim For "SMALLEST" Cluster Size

This will make you "squeeze" the most data in, esp when files are very small

Microsoft's EFI FAT32 specification[10] states that any FAT file system with less than 4085 clusters is FAT12, else any FAT file system with less than 65525 clusters is FAT16, and otherwise it is FAT32. 

FAT-16B - Cluster Size

Upto_8MB128Bytes_Smallest_Possible
8MB-32mb512Bytes

DMF 1024 Floppy is 512bytes

DMF 2048 Floppy is 1kb

NTFS - Cluster Size in NT5 up (Windows 2000+)
Not Ideal For USB FLASH rated 256mb or less
Ideal For USB FLASH rated 512mb or more

7MB-16TB4KB_(@512MB+_NTFS_WINS)
16TB–32TB8 KB
32TB–64TB16 KB
64TB–128TB32 KB
128TB–256TB64 KB

FAT-32 - Cluster Size in NT5 up (Windows 2000+)
Not Ideal For USB FLASH rated 512mb or more
Ideal For USB FLASH rated 256mb or less 

32MB–64MB512 bytes
64MB–128MB1 KB
128MB–256MB2 KB

FAT-32 Cluster Size is 8KB, or More, @512MB and up

exFAT - Cluster Size in NT5 up (Windows 2000+)

32 GB–256 TB128 KB

...

So

DMF Floppy, cant be lower sector/cluster size than 1 KB Best Fit DMF 1024

8MB or Less, but not a floppy, Best Fit FAT-16B

Over 8MB & Under 32MB, Best Fit FAT16B (forced manually or Windows will use FAT-32)

Over 32MB & Under 256MB, Best Fit FAT32

Over 256MB & Under 128GB, Best Fit NTFS

Over 128GB To 256GB (Max volume size support in Windows 10), Best Fit exFAT