I am currently seeing issues with exporting textures from Substance Painter.
I have setup a project where I have 6 'groups' that I turn on/off to export different variants of the texture.
I can happily open a project, open export textures, and then export them to the preset I'm using.
However if I then hide any one of the layer groups, and unhide another layer group, then open the export textures, then try to export them I find that Substance Painter crashes after only a couple of seconds.
The textures are being exported at 2k, and on the first export are working fine.
If I hide the unwanted layer, unhide the wanted layer, change the export location (since I'm exporting them to separate folders to have variants of the texture), then save, exit, reopen Substance, and then export it works fine. But this becomes very slow and tedious if I have to close/re-open Substance to export all 6 variants of the texture sets.
I have attached my latest log.txt and log.back.txt files as well.
Thank you for the detailed repro steps and the log; it's appreciated!
Would you be able to share your project at firstname.lastname@example.org? I can't reproduce your issue on my side, I tried setting up a project similar to what you describe but everything exported as expected when disabling folders.
I may have a more practical solution for you; have you tried using the user channel as your export channel for each of your group presets? This would allow you to one-click export every variant of your texturing.