So I was able to get a 3850 in lab to test and recreate the issue; I had previously upgraded from IOS XE 3.4.6 to 16.12.5b; then I did the below steps;“request platform software package install rollback” or “request platform software package install ...

This device is in production, so I cannot do that, its better to set up a replacement to swap out.

3850#sh ver Cisco IOS Software, IOS-XE Software, Catalyst L3 Switch Software (CAT3K_CAA-UNIVERSALK9-M), Version 03.06.04.E RELEASE SOFTWARE (fc2) Technical Support: http://www.cisco.com/techsupport Copyright (c) 1986-2016 by Cisco Systems, Inc. Compi...

yes used the new and force option but still got the same result;  3850#software install file flash:cat3k_caa-universalk9.16.12.05b.SPA.bin new force Preparing install operation ... [1]: Copying software from active switch 1 to switch 2 [1]: Finished ...

NO, his command is correct, you download the .bin file from Cisco website (there is NO .pkg files to download), the "software install" command will extract the .pkg files from the .bin file and add them to the flash https://www.cisco.com/c/en/us/td/d...