I'd guess that OSD template failure is your first noticeable symptom that the USB stick experienced HW failure, hence you throw it away. I'd check with the manufacturer of the USB stick and check with your PC manufacturer if there is a known fault with either one of them or combined.
Unfortunately I ruled out the USB sticks themselves.... I have tried 3 different brands and that did not correct the issue. Not sure how it could be the PC itself either since once we do get a successful image on it, the USB ports work fine with no issues.
We found out that we needed to inject USB 3.0 drivers into the WinPE boot image which solved the issue. We have not had a failure since.