Having this same issue. It also cropped up out of nowhere. Rendered fine. Went to re-render and got the error. I installed Quicktime 7.6.6 for snow leopard and now instead of getting the error on the first frame, I get it on the last. Running Mac Pro Quad Core (Q6600) with 8 GB ram AE CS5. I am using the render que to create Tiff sequences as a work around, but would like a solution if anyone finds one.