Hi Peter,
I too use S3D for printing with a couple of FFCP printers as it makes life easy - mostly.
I've had quite a few email exchanges since the end of 2016 about QT5Core crashes on Windows when slicing for an FFCP.
There are a few cases here and there where others have suffered the same.
As far as I am aware, no-one ever did get to the bottom of it.
The thread on this -
viewtopic.php?f=9&t=6174&p=37398#p37398
What follows is my setup and my 'solution.'
Perhaps you will have better luck.
My 'graphics design' PC is a beast with 64GB of RAM and running Win7x64Ult. If I dropped it to 16GB, it worked. 32GB+? Nope.
I reinstalled Win7 on a new SSD with ONLY S3D, and the 64GB - crashes.
All memory tests passed fine.
Crucial UK kindly sent me a new test set of memory - same issue.
Ubuntu on the same machine was fine.
As you are well aware now, pretty much every time S3D crashes like this, it corrupts at least the current profile - which is super annoying!
AFAIK, the only way to be sure the corruption does not spread to other profiles is to reset S3D back to standard and start again.
Before you do this, you can *sometimes* save yourself a complet reset by trying to export your profiles one-by-one (no other choice) - if a profile is corrupt, you will either see a zero length file saved (in your directory of choice), or S3D will bomb.
Restart S3D and delete that profile IMMEDIATELY before doing anything else, then restart S3D, and start exporting again.
Rinse and repeat.
When all are backed up, reset S3D.
BEFORE you go loading your saved profiles back in, check their size. If any are really small or zero length - delete them, as soon as you load those up, it will start all over again.
I know this is not a sloution, but after suffering with this almost daily for about a year, both on my graphics PC (and my laptop), I built a cheap i5NUC with Win10home on it and it has been working perfectly now for about a year.
So if you have another PC/Mac you can try, you might be better off using that.
PLEASE don't be tempted to copy over any profiles if you do. You don't want to go through this all again.
(It probably has nothing to do with the memory in the machine, but that was the only consistent thing. The laptop was a monster with 32GB that started out with Win7x64Ult on it, then had the boot HDD replaced with a fresh install of Win10 on it. It was more likely some other hardware, mixed with Windows, but like I say - I gave up)
I hope you find some way through this that works for you.
If you ever find the cause, please share - I really want to know.
Good luck,
Susi
PS
It's always worth punting TechSupport an email to see if they have any fresh ideas.