Hi IMayNeed,
Here is the way to create a .bin file of a bootable
USB Flash Drive (
UFD) and replicate it to any other UFD.
Download ImageUSB from
Tools for OSForensics - ImageUSB - Write an image to multiple USB Flash Drives . Extract it to folder.
The following screenshots are self-explanatory.
( In this hands-on trial, I have imaged my bootable Lucid Puppy on a 1GB Imation UFD, created a lucidpuppy.bin file and wrote it to an HP 8GB UFD ( that was the only UFD that was free.

). I have checked that I can boot Lucid Puppy from the replicated HP UFD. Enjoy.)
CAUTION: Ensure that you have backed up all data on the UFD to which you are replicating since the whole drive will be erased in the writing process.