Summary / Solution - Workspace - Object - Export to Disk - Hangs
Solution that worked for me - edit config.pro to remove All MapKey definintions - keep a separate config.pro for Workspace Export - or - move your company config.pro out of the way completely to reset Pro/E to PTC standard during Object Export.
I don't know which MapKey or MapKey were the problem because when deleting them all worked I did not get more granular.
Thanks for help and hints from folks below
* Michelle McMasters - Relationships set to All sometimes caused an endless loop for her * Mike Bakke - make sure no spaces in any paths - Temp, Tmp, PDM_LDB_PATH etc. (I do not have any spaces) * Gerry Champoux - Toolkit Apps can keep Pro/E from starting in no graphics mode (I was able to leave all of my toolkit_registry_file statements in the config.pro - however - according to std.out none of them started anyway) * Victor Nielson - Jlink programs can keep Pro/E from starting in no graphics mode (I don't have an JLink programs currently)