Are you able to provide a database which produces this problem? We will have to investigate it. My intial investigations did not reveal anything. If you don't like to post the database here, you can send it to mscapex.support@mscsoftware.com.
I tried the export with a trivially simple model that works in APEX IL (1 part - small mesh and some RBE's) and it fails, so the issue is probably not model-related.
resolved by searching C:\Windows\System32 for lib*.dll Found 2 that don't belong there per Mahmud. (libmmd and libifportmd) renamed these two dlls to dll_saved extension. This fixed the problem. Export of bdf now works.
We deliver libifportmd.dll & libmmd.dll but some other non-MSC application had apparently placed older versions of these dll's into C:\Windows\System32 . While copying dll's into customer's C:\Windows\System32 is a bad practice; Apex is trying to put safeguards around it but we have not covered all cases yet. We published the case with libifcoremd.dll previously in a SimCompanion article https://simcompanion.mscsoftware.com/infocenter/index?page=content&id=KB8023348