diff --git a/src/libslic3r/PrintConfig.cpp b/src/libslic3r/PrintConfig.cpp
index 3f977647ce..634164a005 100644
--- a/src/libslic3r/PrintConfig.cpp
+++ b/src/libslic3r/PrintConfig.cpp
@@ -10238,6 +10238,10 @@ int DynamicPrintConfig::update_values_from_single_to_multi(DynamicPrintConfig& m
 
                     for (int index = 0; index < variant_count; index++)
                     {
+                        //variant_count is the variant column width, src_opt the value array;
+                        //they disagree when the source was authored at a different width
+                        if (index >= (int)src_opt->values.size())
+                            break;
                         if (opt->values[index] > src_opt->values[index])
                             opt->values[index] = src_opt->values[index];
                     }
@@ -10255,6 +10259,8 @@ int DynamicPrintConfig::update_values_from_single_to_multi(DynamicPrintConfig& m
 
                     for (int index = 0; index < variant_count; index++)
                     {
+                        if (index >= (int)src_opt->values.size())
+                            break;
                         if (opt->values[index].value > src_opt->values[index].value)
                             opt->values[index] = src_opt->values[index];
                     }
@@ -10449,6 +10455,10 @@ int DynamicPrintConfig::update_values_from_multi_to_multi(DynamicPrintConfig& ne
 
                     for(auto idx : variant_indices){
                         assert(idx < old_count);
+                        //the counts come from the variant columns, the arrays from the options;
+                        //they disagree when a config was authored at a different variant width
+                        if (idx >= old_count || new_variant_index >= (int)opt->values.size())
+                            continue;
                         if (old_values[idx] < opt->values[new_variant_index])
                             opt->values[new_variant_index] = old_values[idx];
                     }
@@ -10479,6 +10489,10 @@ int DynamicPrintConfig::update_values_from_multi_to_multi(DynamicPrintConfig& ne
 
                     for(auto idx : variant_indices){
                         assert(idx < old_count);
+                        //the counts come from the variant columns, the arrays from the options;
+                        //they disagree when a config was authored at a different variant width
+                        if (idx >= old_count || new_variant_index >= (int)opt->values.size())
+                            continue;
                         if (old_values[idx] < opt->values[new_variant_index])
                             opt->values[new_variant_index] = old_values[idx];
                     }
@@ -10509,6 +10523,8 @@ int DynamicPrintConfig::update_values_from_multi_to_multi(DynamicPrintConfig& ne
 
                     for(auto idx : variant_indices){
                         assert(idx < old_count);
+                        if (idx >= old_count || new_variant_index >= (int)opt->values.size())
+                            continue;
                         if (old_values[idx]) //enabled
                             opt->values[new_variant_index] = old_values[idx];
                     }
@@ -10549,6 +10565,15 @@ int DynamicPrintConfig::update_values_from_multi_to_multi_2(const std::vector<st
         same_variant_indices.emplace_back(indices);
     }
 
+    //dst_values below is the destination PRINT preset's per-variant row, sized to its own
+    //print_extruder_variant; dst_extruder_variants is the PRINTER's list. They disagree until
+    //the print preset is re-selected, so size the row to the variant count before indexing it.
+    const size_t dst_variant_count = dst_extruder_variants.size();
+    if (dst_variant_count == 0) {
+        BOOST_LOG_TRIVIAL(error) << __FUNCTION__ << boost::format(", Line %1%: empty destination variant list")%__LINE__;
+        return -1;
+    }
+
     t_config_option_keys keys = this->keys();
     for(auto& key : keys){
         if(key_sets.find(key) == key_sets.end())
@@ -10564,7 +10589,13 @@ int DynamicPrintConfig::update_values_from_multi_to_multi_2(const std::vector<st
             {
                 ConfigOptionFloatsNullable* opt = this->option<ConfigOptionFloatsNullable>(key);
                 auto src_values = opt->values;
-                auto dst_values = dst_config.option<ConfigOptionFloatsNullable>(key) ->values;
+                const auto* dst_opt = dst_config.option<ConfigOptionFloatsNullable>(key);
+                if(!dst_opt){
+                    BOOST_LOG_TRIVIAL(warning) << __FUNCTION__ << boost::format(", Line %1%: %2% missing from destination config")%__LINE__%key;
+                    break;
+                }
+                auto dst_values = dst_opt->values;
+                dst_values.resize(dst_variant_count, ConfigOptionFloatsNullable::nil_value());
                 for(size_t dst_idx =0; dst_idx < same_variant_indices.size(); ++dst_idx){
                     auto& indices = same_variant_indices[dst_idx];
                     if(indices.empty())
@@ -10572,7 +10603,7 @@ int DynamicPrintConfig::update_values_from_multi_to_multi_2(const std::vector<st
                     bool has_value = false;
                     double target_value = std::numeric_limits<double>::max();
                     for(auto idx : indices){
-                        if(opt && idx < opt->values.size() && !opt->is_nil(idx)){
+                        if(idx < (int)opt->values.size() && !opt->is_nil(idx)){
                             has_value = true;
                             target_value = std::min(target_value, src_values[idx]);
                         }
@@ -10588,7 +10619,13 @@ int DynamicPrintConfig::update_values_from_multi_to_multi_2(const std::vector<st
             {
                 ConfigOptionFloatsOrPercentsNullable* opt = this->option<ConfigOptionFloatsOrPercentsNullable>(key);
                 auto src_values = opt->values;
-                auto dst_values = dst_config.option<ConfigOptionFloatsOrPercentsNullable>(key) ->values;
+                const auto* dst_opt = dst_config.option<ConfigOptionFloatsOrPercentsNullable>(key);
+                if(!dst_opt){
+                    BOOST_LOG_TRIVIAL(warning) << __FUNCTION__ << boost::format(", Line %1%: %2% missing from destination config")%__LINE__%key;
+                    break;
+                }
+                auto dst_values = dst_opt->values;
+                dst_values.resize(dst_variant_count, ConfigOptionFloatsOrPercentsNullable::nil_value());
                 for(size_t dst_idx =0; dst_idx < same_variant_indices.size(); ++dst_idx){
                     auto& indices = same_variant_indices[dst_idx];
                     if(indices.empty())
@@ -10596,7 +10633,7 @@ int DynamicPrintConfig::update_values_from_multi_to_multi_2(const std::vector<st
                     bool has_value = false;
                     FloatOrPercent target_value{9999.f, true};
                     for(auto idx : indices){
-                        if(opt && !opt->is_nil(idx)){
+                        if(idx < (int)opt->values.size() && !opt->is_nil(idx)){
                             has_value = true;
                             target_value = src_values[idx].value < target_value.value ? src_values[idx] : target_value;
                         }
@@ -10612,15 +10649,21 @@ int DynamicPrintConfig::update_values_from_multi_to_multi_2(const std::vector<st
             {
                 ConfigOptionBoolsNullable* opt = this->option<ConfigOptionBoolsNullable>(key);
                 auto src_values = opt->values;
-                auto dst_values = dst_config.option<ConfigOptionBoolsNullable>(key) ->values;
+                const auto* dst_opt = dst_config.option<ConfigOptionBoolsNullable>(key);
+                if(!dst_opt){
+                    BOOST_LOG_TRIVIAL(warning) << __FUNCTION__ << boost::format(", Line %1%: %2% missing from destination config")%__LINE__%key;
+                    break;
+                }
+                auto dst_values = dst_opt->values;
+                dst_values.resize(dst_variant_count, ConfigOptionBoolsNullable::nil_value());
                 for(size_t dst_idx =0; dst_idx < same_variant_indices.size(); ++dst_idx){
                     auto indices = same_variant_indices[dst_idx];
                     if(indices.empty())
                         continue;
                     bool has_value = false;
-                    bool target_value;
+                    bool target_value = false;
                     for(auto idx : indices){
-                        if(opt && !opt->is_nil(idx)){
+                        if(idx < (int)opt->values.size() && !opt->is_nil(idx)){
                             has_value = true;
                             target_value = src_values[idx];
                             break;
diff --git a/tests/libslic3r/test_config_variant_expansion.cpp b/tests/libslic3r/test_config_variant_expansion.cpp
index dd7de2af44..28901702cc 100644
--- a/tests/libslic3r/test_config_variant_expansion.cpp
+++ b/tests/libslic3r/test_config_variant_expansion.cpp
@@ -479,3 +479,84 @@ TEST_CASE("update_values_to_printer_extruders_for_multiple_filaments resolves pe
         REQUIRE(config.option<ConfigOptionInts>("filament_self_index")->values == std::vector<int>({1, 2}));
     }
 }
+
+// update_values_from_multi_to_multi_2 walks the DESTINATION PRINTER's variant list while writing
+// into a row taken from the destination PRINT preset, whose arrays are sized to its own
+// print_extruder_variant. Those two widths disagree until the print preset is re-selected for the
+// new printer -- Tab::load_current_preset() runs this migration first -- so a project authored on
+// a single-variant printer, opened and switched to a wider one, wrote past the end of the row.
+TEST_CASE("update_values_from_multi_to_multi_2 sizes the destination row to the variant count",
+          "[Config][VariantExpansion]")
+{
+    const std::vector<std::string> src_variants{"Direct Drive Standard"};
+    const std::vector<std::string> dst_variants{"Direct Drive Standard", "Direct Drive High Flow",
+                                                "Direct Drive Standard", "Direct Drive High Flow"};
+    const std::set<std::string>    keys{"outer_wall_speed"};
+
+    // The per-object override as authored on the single-variant printer.
+    const auto object_override = [] {
+        DynamicPrintConfig c;
+        c.option<ConfigOptionFloatsNullable>("outer_wall_speed", true)->values = {42.};
+        return c;
+    };
+
+    SECTION("a row narrower than the variant list is grown, not overrun") {
+        DynamicPrintConfig object_config = object_override();
+        DynamicPrintConfig dst;
+        dst.option<ConfigOptionFloatsNullable>("outer_wall_speed", true)->values = {200.};
+
+        REQUIRE(object_config.update_values_from_multi_to_multi_2(src_variants, dst_variants, dst, keys) == 0);
+
+        const auto& out = object_config.option<ConfigOptionFloatsNullable>("outer_wall_speed")->values;
+        REQUIRE(out.size() == dst_variants.size());
+        // Both "Direct Drive Standard" columns match the source variant, so they take the override.
+        CHECK(out[0] == Catch::Approx(42.));
+        CHECK(out[2] == Catch::Approx(42.));
+        // The High Flow columns have no matching source variant: nil, so the destination keeps
+        // tracking the print preset rather than being pinned to another variant's value.
+        CHECK(std::isnan(out[1]));
+        CHECK(std::isnan(out[3]));
+    }
+
+    // The regression guard: where the row already matches the variant list -- every case that was
+    // not corrupting the heap -- the resize is a no-op and the output is unchanged.
+    SECTION("a correctly sized row is untouched") {
+        DynamicPrintConfig object_config = object_override();
+        DynamicPrintConfig dst;
+        dst.option<ConfigOptionFloatsNullable>("outer_wall_speed", true)->values = {200., 500., 210., 510.};
+
+        REQUIRE(object_config.update_values_from_multi_to_multi_2(src_variants, dst_variants, dst, keys) == 0);
+
+        const auto& out = object_config.option<ConfigOptionFloatsNullable>("outer_wall_speed")->values;
+        REQUIRE(out.size() == 4);
+        CHECK(out[0] == Catch::Approx(42.));    // matched -> override
+        CHECK(out[1] == Catch::Approx(500.));   // unmatched -> preset value preserved
+        CHECK(out[2] == Catch::Approx(42.));
+        CHECK(out[3] == Catch::Approx(510.));
+    }
+
+    // is_nil(idx) indexes values[idx] with no bounds check, so a source shorter than its own
+    // variant list read out of range before the guard was added.
+    SECTION("a source shorter than its variant list is read in range") {
+        DynamicPrintConfig object_config = object_override();   // one value...
+        DynamicPrintConfig dst;
+        dst.option<ConfigOptionFloatsNullable>("outer_wall_speed", true)->values = {200., 500.};
+
+        REQUIRE(object_config.update_values_from_multi_to_multi_2(
+            {"Direct Drive Standard", "Direct Drive Standard"},   // ...but two source variants
+            {"Direct Drive Standard", "Direct Drive High Flow"}, dst, keys) == 0);
+
+        const auto& out = object_config.option<ConfigOptionFloatsNullable>("outer_wall_speed")->values;
+        REQUIRE(out.size() == 2);
+        CHECK(out[0] == Catch::Approx(42.));
+        CHECK(out[1] == Catch::Approx(500.));
+    }
+
+    SECTION("an empty destination variant list is refused") {
+        DynamicPrintConfig object_config = object_override();
+        DynamicPrintConfig dst;
+        dst.option<ConfigOptionFloatsNullable>("outer_wall_speed", true)->values = {200.};
+
+        CHECK(object_config.update_values_from_multi_to_multi_2(src_variants, {}, dst, keys) == -1);
+    }
+}