I copy my working Raspberry Pi disk to another Raspberry Pi SD card by using "Win32 Disk Imager", the working image is about 3.8 G, but the read image is much bigger size (about 15 G) and I can't write it to another SD card.
How to make the copied image same as the original image?
Perhaps take a step back and use the SD Card Copier utility that is installed as part of RasPiOS.
The image you have created is not of the active content alone, but of the entire physical 'disk'.
And the working capacity of an SD Card is not exact. Some are larger, some are smaller, while still statistically "16Gb".
An alternative is to try lots of 16Gb microSD cards until you find one whose actual working capacity is sufficient. (Or use a 32Gb card.)
Statistics: Posted by B.Goode — Sun Jan 28, 2024 12:54 pm