diff --git a/pcbnew/autorouter/spread_footprints.cpp b/pcbnew/autorouter/spread_footprints.cpp
index 7e573304da..370f38e188 100644
--- a/pcbnew/autorouter/spread_footprints.cpp
+++ b/pcbnew/autorouter/spread_footprints.cpp
@@ -5,7 +5,7 @@
  * Copyright (C) 2013 SoftPLC Corporation, Dick Hollenbeck <dick@softplc.com>
  * Copyright (C) 2013 Wayne Stambaugh <stambaughw@verizon.net>
  *
- * Copyright (C) 1992-2022 KiCad Developers, see AUTHORS.txt for contributors.
+ * Copyright (C) 1992-2023 KiCad Developers, see AUTHORS.txt for contributors.
  *
  * This program is free software; you can redistribute it and/or
  * modify it under the terms of the GNU General Public License
@@ -35,6 +35,7 @@
  */
 
 #include <spread_footprints.h>
+#include <optional>
 #include <algorithm>
 #include <refdes_utils.h>
 #include <string_utils.h>
@@ -77,12 +78,13 @@ static bool compareFootprintsbyRef( FOOTPRINT* ref, FOOTPRINT* compare )
 
 
 // Spread a list of rectangles inside a placement area
-rectpack2D::rect_wh spreadRectangles( rect_vector& vecSubRects, int areaSizeX, int areaSizeY )
+std::optional<rectpack2D::rect_wh> spreadRectangles( rect_vector& vecSubRects, int areaSizeX,
+                                                     int areaSizeY )
 {
     areaSizeX /= scale;
     areaSizeY /= scale;
 
-    rectpack2D::rect_wh result;
+    std::optional<rectpack2D::rect_wh> result;
 
     int max_side = std::max( areaSizeX, areaSizeY );
 
@@ -107,7 +109,7 @@ rectpack2D::rect_wh spreadRectangles( rect_vector& vecSubRects, int areaSizeX, i
                 make_finder_input( max_side, discard_step, report_successful, report_unsuccessful,
                                    rectpack2D::flipping_option::DISABLED ) );
 
-        if( anyUnsuccessful )
+        if( !result || anyUnsuccessful )
         {
             max_side = (int) ( max_side * 1.2 );
             continue;
diff --git a/thirdparty/rectpack2d/rectpack2d/best_bin_finder.h b/thirdparty/rectpack2d/rectpack2d/best_bin_finder.h
index a76b47d1f6..fe17ca7dcf 100644
--- a/thirdparty/rectpack2d/rectpack2d/best_bin_finder.h
+++ b/thirdparty/rectpack2d/rectpack2d/best_bin_finder.h
@@ -1,4 +1,5 @@
 #pragma once
+#include <optional>
 #include <variant>
 #include <cassert>
 #include "rect_structs.h"
@@ -213,7 +214,7 @@ namespace rectpack2D {
 		class F,
 		class I
 	>
-	rect_wh find_best_packing_impl(F for_each_order, const I input) {
+	std::optional<rect_wh> find_best_packing_impl(F for_each_order, const I input) {
 		const auto max_bin = rect_wh(input.max_bin_side, input.max_bin_side);
 
 		OrderType* best_order = nullptr;
@@ -258,9 +259,8 @@ namespace rectpack2D {
 			}
 		});
 
+		if( best_order != nullptr )
 		{
-			assert(best_order != nullptr);
-			
 			root.reset(best_bin);
 
 			for (auto& rr : *best_order) {
@@ -281,6 +281,10 @@ namespace rectpack2D {
 			}
 
 			return root.get_rects_aabb();
-		}
+        }
+        else
+        {
+            return std::nullopt;
+        }
 	}
 }
diff --git a/thirdparty/rectpack2d/rectpack2d/finders_interface.h b/thirdparty/rectpack2d/rectpack2d/finders_interface.h
index c3ef8217db..3bd61e997d 100644
--- a/thirdparty/rectpack2d/rectpack2d/finders_interface.h
+++ b/thirdparty/rectpack2d/rectpack2d/finders_interface.h
@@ -69,7 +69,7 @@ namespace rectpack2D {
 	*/
 
 	template <class empty_spaces_type, class F, class G, class Comparator, class... Comparators>
-	rect_wh find_best_packing(
+	std::optional<rect_wh> find_best_packing(
 		std::vector<output_rect_t<empty_spaces_type>>& subjects,
 		const finder_input<F, G>& input,
 
@@ -122,7 +122,7 @@ namespace rectpack2D {
 	*/
 
 	template <class empty_spaces_type, class F, class G>
-	rect_wh find_best_packing(
+	std::optional<rect_wh> find_best_packing(
 		std::vector<output_rect_t<empty_spaces_type>>& subjects,
 		const finder_input<F, G>& input
 	) {