Might I suggest that rather than making images of these flash drives, just save the macOS installer app from which the flash drives were made. In my situation, that is what I do.
A great suggestion and it would work perfectly, but as you went on to point out, it doesn't fix the overall issue of the imaging tool not working.
Frankly, based on what you have posted, I have no idea why it doesn't work unless there is something else at play.
I agree, there is some fundamental issue that is causing this. I'm hoping someone else has had and resolved this issue before.
When you selected the menu option to make a new image from the disk, do you recall what the default options were? On my system they were: read-only and None.
Yes, mine are the same and it saves to documents as a default.
I wonder if there isn't something on the USB flash drives that is preventing the process from working. You might run Get Info on them to check the permissions. Mine shows: Owner is "...(Me)" with r/w; Group is "staff" with r/w; and Everyone is "Read only". At the very bottom the Ignore ownership on this volume options is checked.
Mine is the same for all of them. I suspected they might be the issue. So, I took a brand new flash drive straight from the package and copied a file onto it. Then, I tried to image it and ran into the same issue exactly. So I erased it and partitioned it to default values, exFAT for a 32gb drive. Again, I tried to image it and again I had the exact same issue. Each of the four drives are made by different manufacturers.
I believe it's fair to say that I have eliminated the drives as an issue. I have also tried all of the drives on each of the usb ports on the computer and the issue persists.
It is very frustrating.
Again, thank you for taking the time to reply.