I did find similar issues reported, including Sept. 2025, with no resolution cited. This issue seems to be the same symptoms:
Trying to create, either direct to a USB flash drive, or to an .iso file, results in the progress bar quickly reaching 14%, then a pause, then reverting back to the Virus Scan screen. Only if clicking back to Rescue Disk is an error message revealed “We couldn’t couldn’t create your Rescue Disk. An unexpected error occurred. Please try again later.” and and “Ok” button.
Upon starting (to a flash drive), the drive’s activity light illuminates briefly at the beginning then quickly stops.
Avast Business Antivirus (title of the app window), Avast Business Security in the taskbar icon item (the one as the open program. Originally CloudCare. I CAN manually update virus defs and the program (though it doesn’t update anything today and is a version from Jan. 27th.
I’ve waited “a while” and tried again, no joy. I tried with all VPN to the internet disconnected.
Sadly, I formatted my flash drive for troubleshooting; now I don’t even have a fairly recently created one. And since it usually works, I don’t have an .iso anywhere close to recent. A quick internet search reveals a Rescue Disk cannot be downloaded directly, instead must be created from within an installed instance.