This is a pesky issue, for sure. It seems that there is no one cure -- so nothing to do but try different stuff. At least you are able to export in pro res. As for the difficulty in sharing the large pro res files, you could use Handbrake to reconvert them back to Mp4, thereby reducing the high bitrate that is making the pro res files so large. It's a pain, I know.
The codecs seem fine, although Mp3 sometimes can be problematic. Since you have been able export these same clips before I don't think that Mp3 is the issue. You might try taking one of the clips before importing it into iMovie, and using the free download Handbrake to reconvert it into the same Mp4 codec. For some reason that sometimes resets the codec and makes it work in iMovie. See if that will export successfully.
Another thing you can try, particularly since you have recently updated your operating system, is to repair permissions using the Disc Utility app found in your Mac's Utilities folder. Doing that has cured crashing problems, and so I am wondering if it might cure an export problem. Might as well try it since it is easy to do.
The only other things I can think of that we haven't tried are 1) starting up in safe mode, and then closing and restarting in normal mode, and 2) using the diagnostics program on your Mac to rule out hardware issues.
From your post and others, I am getting the feeling that this issue is something that Apple might need to correct with an update. However, let's not give up yet.
-- Rich