diff --git a/api-extractor/report/hls.js.api.md b/api-extractor/report/hls.js.api.md
index b9325c66dd9..176ebd293b8 100644
--- a/api-extractor/report/hls.js.api.md
+++ b/api-extractor/report/hls.js.api.md
@@ -726,6 +726,7 @@ export type BufferControllerConfig = {
     frontBufferFlushThreshold: number;
     liveDurationInfinity: boolean;
     liveBackBufferLength: number | null;
+    maxAppendSize: number;
 };
 
 // Warning: (ae-missing-release-tag) "BufferCreatedData" is part of the package's API, but it is missing a release tag (@alpha, @beta, @public, or @internal)
diff --git a/src/config.ts b/src/config.ts
index a6906e648c6..9c533e5eb0d 100644
--- a/src/config.ts
+++ b/src/config.ts
@@ -69,6 +69,7 @@ export type BufferControllerConfig = {
    * @deprecated use backBufferLength
    */
   liveBackBufferLength: number | null;
+  maxAppendSize: number;
 };
 
 export type CapLevelControllerConfig = {
@@ -392,6 +393,7 @@ export const hlsDefaultConfig: HlsConfig = {
   maxBufferLength: 30, // used by stream-controller
   backBufferLength: Infinity, // used by buffer-controller
   frontBufferFlushThreshold: Infinity,
+  maxAppendSize: Infinity, // used by buffer-controller
   startOnSegmentBoundary: false, // used by stream-controller
   nextAudioTrackBufferFlushForwardOffset: 0.25, // used by stream-controller
   maxBufferSize: 60 * 1000 * 1000, // used by stream-controller
diff --git a/src/controller/buffer-controller.ts b/src/controller/buffer-controller.ts
index 31640e9ae8d..24a395639e0 100755
--- a/src/controller/buffer-controller.ts
+++ b/src/controller/buffer-controller.ts
@@ -22,6 +22,7 @@ import {
   isCompatibleTrackChange,
   isManagedMediaSource,
 } from '../utils/mediasource-helper';
+import { splitAppendData } from '../utils/mp4-tools';
 import { stringify } from '../utils/safe-json-stringify';
 import type { FragmentTracker } from './fragment-tracker';
 import type { HlsConfig } from '../config';
@@ -779,8 +780,30 @@ transfer tracks: ${stringify(transferredTracks, (key, value) => (key === 'initSe
     event: Events.BUFFER_APPENDING,
     eventData: BufferAppendingData,
   ) {
+    const { data, type } = eventData;
+    const { maxAppendSize } = this.hls.config;
+
+    // Split large fMP4 segments into smaller chunks to avoid QuotaExceededError.
+    // Each chunk becomes a separate operation with full error handling.
+    if (isFinite(maxAppendSize) && data.byteLength > maxAppendSize) {
+      const chunks = splitAppendData(data, maxAppendSize);
+      if (chunks.length > 1) {
+        this.log(
+          `Splitting large ${type} append (sn:${eventData.frag.sn}, ` +
+            `${(data.byteLength / 1e6).toFixed(1)}MB) into ${chunks.length} chunks`,
+        );
+        for (let i = 0; i < chunks.length; i++) {
+          this.onBufferAppending(event, {
+            ...eventData,
+            data: chunks[i],
+          });
+        }
+        return;
+      }
+    }
+
     const { tracks } = this;
-    const { data, type, parent, frag, part, chunkMeta, offset } = eventData;
+    const { parent, frag, part, chunkMeta, offset } = eventData;
     const chunkStats = chunkMeta.buffering[type];
     const { sn, cc } = frag;
     const bufferAppendingStart = self.performance.now();
diff --git a/src/utils/mp4-tools.ts b/src/utils/mp4-tools.ts
index 4d6d836db2f..c526b4af5e2 100644
--- a/src/utils/mp4-tools.ts
+++ b/src/utils/mp4-tools.ts
@@ -41,6 +41,119 @@ export function readUint32(buffer: Uint8Array, offset: number): number {
   return val < 0 ? 4294967296 + val : val;
 }
 
+/**
+ * Read the size of an fMP4 box at the given offset, handling both standard
+ * and 64-bit extended sizes. Returns the box size in bytes, or 0 if the
+ * box header is invalid or truncated.
+ */
+export function readMp4BoxSize(
+  data: Uint8Array,
+  pos: number,
+  end: number,
+): number {
+  if (pos + 8 > end) {
+    return 0;
+  }
+  const size = readUint32(data, pos);
+  if (size === 0) {
+    return end - pos;
+  }
+  if (size === 1 && pos + 16 <= end) {
+    const hi = readUint32(data, pos + 8);
+    return hi > 0 ? end - pos : readUint32(data, pos + 12);
+  }
+  if (size < 8 || pos + size > end) {
+    return 0;
+  }
+  return size;
+}
+
+/**
+ * Try to split data at fMP4 top-level box boundaries into chunks of at
+ * most maxBytes. Returns null if box-boundary splitting cannot produce
+ * chunks that all fit within maxBytes (e.g. a single giant mdat box).
+ */
+export function splitAtBoxBoundaries(
+  data: Uint8Array<ArrayBuffer>,
+  maxBytes: number,
+): Uint8Array<ArrayBuffer>[] | null {
+  if (data.byteLength < 8) {
+    return null;
+  }
+  const chunks: Uint8Array<ArrayBuffer>[] = [];
+  const end = data.byteLength;
+  let chunkStart = 0;
+  let pos = 0;
+
+  while (pos < end) {
+    const boxSize = readMp4BoxSize(data, pos, end);
+    if (boxSize === 0) {
+      break;
+    }
+    if (pos > chunkStart && pos - chunkStart + boxSize > maxBytes) {
+      chunks.push(
+        new Uint8Array(
+          data.buffer,
+          data.byteOffset + chunkStart,
+          pos - chunkStart,
+        ),
+      );
+      chunkStart = pos;
+    }
+    pos += boxSize;
+  }
+
+  if (chunkStart < end) {
+    chunks.push(
+      new Uint8Array(
+        data.buffer,
+        data.byteOffset + chunkStart,
+        end - chunkStart,
+      ),
+    );
+  }
+
+  const allFit =
+    chunks.length > 1 && !chunks.some((c) => c.byteLength > maxBytes);
+  return allFit ? chunks : null;
+}
+
+/**
+ * Split a large buffer into chunks of at most maxBytes.
+ * Tries to split at fMP4 top-level box boundaries first. If the data
+ * contains a single box larger than maxBytes (e.g. a giant mdat), falls
+ * back to naive byte splitting — MSE SourceBuffer handles reassembly of
+ * partial boxes internally.
+ */
+export function splitAppendData(
+  data: Uint8Array<ArrayBuffer>,
+  maxBytes: number,
+): Uint8Array<ArrayBuffer>[] {
+  if (data.byteLength <= maxBytes) {
+    return [data];
+  }
+
+  const boxChunks = splitAtBoxBoundaries(data, maxBytes);
+  if (boxChunks) {
+    return boxChunks;
+  }
+
+  // Fallback: naive byte splitting. MSE SourceBuffer handles partial box
+  // reassembly across sequential appendBuffer() calls.
+  const chunks: Uint8Array<ArrayBuffer>[] = [];
+  const end = data.byteLength;
+  for (let offset = 0; offset < end; offset += maxBytes) {
+    chunks.push(
+      new Uint8Array(
+        data.buffer,
+        data.byteOffset + offset,
+        Math.min(maxBytes, end - offset),
+      ),
+    );
+  }
+  return chunks;
+}
+
 export function readUint64(buffer: Uint8Array, offset: number) {
   let result = readUint32(buffer, offset);
   result *= Math.pow(2, 32);