I’ve never had this issue and I construct FTransforms all the time - only difference (I can’t see it making a difference with the exception though) is that I pass a FVector(1,1,1) for the Scale3D (3rd parameter).
In this example, “FQuat NewRot” is really not normalized, which is why an error occurs, but in my case it is normalized.
The problem is not in the rotation values, if that were the case, it would break at the first generation, but it breaks at different times for me.
There is an assumption that there is a memory overflow due to the created instances, but I’m not at all sure about it and I don’t know how to avoid it.