How big is "big-ish"?
Do you have the same crash problem when saving as other formats? (Parasolid, IGES, etc)
Did the problem exist before the Windows & GC driver updates?
Can you do a system restore to before the updates?
I think I figured it out, its not a Solidworks problem. It is an assembly w/ multiple configurations, the .STEP of a given config is about 40MB
The problem is a particular part supplied by the client, I imported from IGES, and when I go to save as .STEP with that particular part, it crashes with the memory error. In fact, just that part alon will crash SW when trying to save. Thank god my SW is fine, its a problem with the ruddy file supplied by the client.
The weird thing was that it gives an out of memory error when crashing. So false alarm