TLDR I found a solution - bottom of this post
I had been changing the result of Aspect Ratio in my formula from this:
to this:2.40.1
Since colons are not allowed in filenames on mac I had been using the ratio character which is allowed, but that stopped working in my format sometime around Aug 25, 2021 and just noticed this week2.40∶1


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{info:video[0].displayAspectRatioString.colon(":").replace('?', '∶')}
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{ar.toString().replace(':' '∶')}
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{ar.toString().replace('1', '∶1')}
Other interesting and unexpected formatting results...2.40∶∶1
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ar.toString().replace('1', '-1')}
2.40∶-1
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ar.toString().replace('∶1', '-1')
Produces
2.40-1

After trying many things... the following works - not sure what's going on behind the scenes or what's changed though

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{ar.toString().replace('∶1', '"∶"1')}
That is: "2, period, 4, 0, ratio, 1"2.40∶1