Hi Jonathan,
This issue began to rear its ugly head when ESRI released ArcGIS 9.1. Our bridge for GRID format seemed to work fine up until that point. Something in the new version of ArcGIS broke the bridge. We're still working on a way to resolve this issue (it's elusive), but for now I can offer a few ways to deal with it:
1) We have created a plug-in for ArcGIS that allows it to read ENVI format files without the need to export to GRID. You can grab it from our downloads page under "All ENVI Modules and Plugins."
2) Modify your workflow slightly: Do not work from files sitting in folders on your desktop. Instead, keep your files somewhere else (C:\data, for example). We think the root of the problem is some funky interaction between the IDL Open/Save dialog, the Windows Desktop, and Windows Tooltips (those info bubbles that pop up when you pass your mouse pointer over a file). Of those, the Tooltips appear to be the biggest culprit. It can also help if you don't pause for too long between navigating to particular files and folders.
If you require any further assistance, please feel free to contact Tech Support and we'd be happy to help in any way we can.
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