The engine will crash when cluster bounds barely overlap.
Place a sphere in the scene at (X=-50.000000,Y=-140.000000,Z=80.000000)
Place a second sphere at (X=-50.000000,Y=-313.200012,Z=80.000000)
In World Settings, check "Enable Hierarchical LOD System"
In the Hierarchical LOD Setup section, change the Cluster generation settings for HLOD Level 0 to have "Min Number Of Actors Build" set to 1
Open the HLOD Outliner, then click "Generate Clusters"
> UE4Editor-UnrealEd.exe.patch_2!CalculateOverlap(const FSphere &, const float, const FSphere &, const float) Line 76 C++
 [Inline Frame] UE4Editor-UnrealEd.exe.patch_2!CalculateFillingFactor(const FSphere &, const float, const FSphere &, const float) Line 85 C++
 UE4Editor-UnrealEd.exe.patch_2!FLODCluster::FLODCluster(AActor *, AActor *) Line 124 C++
 UE4Editor-UnrealEd.dll!FHierarchicalLODBuilder::InitializeClusters(ULevel *, const int, float, const bool, const bool) Line 413 C++
 UE4Editor-UnrealEd.dll!FHierarchicalLODBuilder::BuildClusters(ULevel *, const bool) Line 265 C++
 UE4Editor-UnrealEd.dll!FHierarchicalLODBuilder::PreviewBuild() Line 119 C++
 UE4Editor-HierarchicalLODOutliner.dll!HLODOutliner::SHLODOutliner::HandlePreviewHLODs() Line 771 C++
There's no existing public thread on this issue, so head over to Questions & Answers just mention UE-80400 in the post.
| 1 | 
| Component | UE - World Creation - Worldbuilding Tools - HLOD | 
|---|---|
| Affects Versions | 4.23 | 
| Target Fix | 4.23.1 | 
| Created | Sep 16, 2019 | 
|---|---|
| Resolved | Sep 17, 2019 | 
| Updated | Feb 27, 2020 |