Mine happens as well. It has been very consistent. I cannot pinpoint exactly to make it reproducible. If I use one or two tools in PI, exit PI, I am able to restart PI. But if I process an image using many PI tools, exit PI, I will not be able to restart PI but I can restart using "PixInsight - New Insrance".
I know Juan has blamed Windows OS or graphics driver but if I revert back to PI version 1.8.4, I have absolutely no issues. I am still using 1.8.5 because I like the new PCC tool very much.
My computer is a home built Intel i7 (over 2000 pins), Windows 10 64 bit with latest Windows Update, Radeon graphics card using latest driver as of few days ago. I don't have anti-virus software running. No bloatware of any kind is installed.
I also have an HP laptop with i5 CPU, Windows 10 with latest updates and shared RAM graphics chip and so far PI version 1.8.5 is working. I don't use laptop for processing images, I only use it for capturing images and controlling the mount, focuser and camera.
Peter