How to determine the best byte size for the dd command
As Chris S wrote in this answer the optimum block size is hardware dependent. In my experience it is always greater than the default 512 bytes. If your working with raw devices then the overlying file system geometry will have no effect. I've used the script below to help 'optimize' the block size of dd.
#!/bin/bash
#
#create a file to work with
#
echo "creating a file to work with"
dd if=/dev/zero of=/var/tmp/infile count=1175000
for bs in 1k 2k 4k 8k 16k 32k 64k 128k 256k 512k 1M 2M 4M 8M
do
echo "Testing block size = $bs"
dd if=/var/tmp/infile of=/var/tmp/outfile bs=$bs
echo ""
done
rm /var/tmp/infile /var/tmp/outfile
Unfortunately the perfect size will depend on your system bus, hard drive controller, the particular drive itself, and the drivers for each of those. The only way to find the perfect size is to keep trying different sizes. Fair warning that some devices only support one block size, though this is rare, and usually drivers make up the difference anyway.
I find that block size of 2^15 or 2^16 work best for my WDC (8mb cache) SATA drives connected to a Adaptec SAS RAID controller, 4x PCIe, 64-bit FreeBSD 8.0-STABLE. But for my cheap old thumb drive, sizes of 2^10 seem to be fastest.
The "perfect size" is almost always a power of two.