How to resolve 'file not found error'

I’m resurrecting an old thread here, but this has become such an issue for me that I have abandoned reality capture as a professional software.
Here’s my workflow:

Capture project or receive data from another source on an external drive.

Create folder for the project on the D drive titled “Project X” with sub-folders “Data” and “ProjectFiles”

Import all data into “Data”

Disconnect external drive.

Start RC and load “Data” folder.

SAVE into “ProjectFiles” folder.

Complete project.

I’ve had a recent batch of 3 projects, all completed this way, give the file not found error and I haven’t been able to resolve. As soon as I close a project, it’s 50/50 whether or not I can open it again.

It’s mission critical for me that I can actually export deliverables for clients. I’ve tried reloading RC. I’ve checked the integrity of my memory and drives. If I can’t finish the project beginning to end in one session, I don’t even bother trying anymore. I’ve moved my workflow almost entirely to metashape now, which takes longer and is less flexible, but is reliable.