davidm Unfortunately, based on the information provided, it is difficult to determine the exact cause of the issue. However, it is likely related to the use of Polygons in the Output - Packing option combined with complex conditions, which may be leading to inefficient packing results.
The texture packing process has a limit on the number of attempts it can make, so if the conditions are overly complex, packing efficiency may be reduced. That said, this kind of issue is much less common in version 4.2, so the problem may not be solely due to the use of polygon packing but rather a combination of multiple factors.
If you would like to identify the exact cause, please send the files that reproduce the issue via email: contact@esotericsoftware.com
Please include the URL of this forum thread in the email so we know the context. Then we can take a look at what's wrong.
