Rule areas in footprints generate excessively large outlines

My footprints with rule areas (keep outs) cause the BOM to generate with extremely large footprint outlines.

Removing the rule area from each footprint will remove all errors with the BOM, but this is not ideal for my design.

Interestingly, this error will sometimes be fixed when I remove the rule area and place it back. The first time I generate a BOM after, the outline occasionally generates correctly. However, I am not able to find a pattern with this behaviour (half of them will have correct outlines, half will not).

Placing the footprints on a new board by itself does not generate issues.

Placing the same footprints on a different project, or adding rule areas to footprints on an existing project will replicate this issue on that project.

This seems to be a common error and is independent of generating a BOM file when opening a KiCAD project the first time, or generating multiple times through a single session. The rule areas placed in the PCB Editor do not seem to affect the generation of the BOM.

I am running KiCAD 10.0.6, Plugin 2.12.0, and the latest version of MacOS.

Thank you!

Start by reproducing the oversized footprint outlines during BOM generation with KiCad rule areas, then compare affected footprints with those on a standalone board. Check whether repeated generations and moving rule areas change the result. Done means rule areas no longer produce incorrect large outlines consistently across projects and sessions.