The export failure “Something went wrong when Removing Overlap in glyph X” is particularly annoying because it leaves you guessing what exactly was interpolating wrong. I might change the axis value of an instance and all of a sudden a glyph that was fine previously no longer interpolates.
Could you output or highlight any of: The master, the segment, the points near to, or any other helpful info for this error?
Even better would be an advanced version of the “Show Master Compatibility” that will also find such interpolation problems.