Kali live - ISO mode USB Installer halts at grub prompt - real HW

Hi,
I downloaded Kali everything ISO which is about 10GB from the Live Kali download section.
On Windows 10 I used rufus tool to create bootable USB. Rufus tells me that the ISO is hybrid and can be written to USB in either dd mode or ISO mode. Rufus recommends ISO mode.

When I use dd mode the USB works fine on real hardware.
When I use ISO mode the same USB boots perfectly fine in vmware virtual machine but on my real asrock b450m board PC it just boots to grub prompt.
Does anyone know why?

The 3GB live ISO does not have this issue. Only 10GB everything live ISO.

So install from 3GB and then add the rest after

dd mode is working fine. I am trying to understand the cause of this issue with ISO mode only on everything ISO file.
When I use ISO mode the same USB boots perfectly fine in vmware virtual machine but on my real asrock b450m board PC it just boots to grub prompt.