Hello, thank you both of you for doing some of your own digging on this issue as I’ve been away from the computer for thanksgiving holiday here in the US.
I see mention above of a potential conflict with PHP 7.4. Is this still occuring or did that end up not being related?
As far as this ‘fixing itself’. There are a couple situations where the plugin will re-attempt getting the icons from FontAwesome. One of those situations is when you switch from 5.x to 4.x, or vice versa. So switching the version back and forth can be a way to ‘retry’ caching the icons. Perhaps this explains part of what you are seeing things fixing themselves.
As far as why there was a failure to begin with, is much trickier to say at this point. It is possible that some downtime of one of the CDNs that this plugin utilizes was to blame. I have seen a number of news headlines about Amazon AWS outages in the past few days which seems like a possible correlation.
My longterm goals with this plugin is to migrate to using the FontAwesome APIs for getting the icons and to also use their ‘font kit’ for defining which version should be loaded.