diff --git a/.changeset/popout-widget-hide-restore.md b/.changeset/popout-widget-hide-restore.md
new file mode 100644
index 00000000000..49b879bc7b5
--- /dev/null
+++ b/.changeset/popout-widget-hide-restore.md
@@ -0,0 +1,7 @@
+---
+"@itwin/appui-react": patch
+---
+
+Fixed a popped-out (child window) widget docking back to its panel instead of remaining popped out after it was hidden (`WidgetState.Hidden`) and then shown again.
+
+Also enforced a minimum popout window size (200x200), matching the existing minimum used for floating widgets, to prevent popout windows from progressively shrinking to an unusably small size across repeated pop-out/dock cycles.
diff --git a/docs/storybook/src/widget/PopoutRestore.stories.tsx b/docs/storybook/src/widget/PopoutRestore.stories.tsx
new file mode 100644
index 00000000000..33ab6acef60
--- /dev/null
+++ b/docs/storybook/src/widget/PopoutRestore.stories.tsx
@@ -0,0 +1,34 @@
+/*---------------------------------------------------------------------------------------------
+ * Copyright (c) Bentley Systems, Incorporated. All rights reserved.
+ * See LICENSE.md in the project root for license terms and full copyright notice.
+ *--------------------------------------------------------------------------------------------*/
+import type { Meta, StoryObj } from "@storybook/react-vite";
+import { PopoutRestoreStory } from "./PopoutRestore";
+import { AppUiDecorator } from "../Decorators";
+import { Page } from "../AppUiStory";
+
+const meta = {
+  title: "Widget/PopoutRestore",
+  component: PopoutRestoreStory,
+  tags: ["autodocs"],
+  decorators: [AppUiDecorator],
+  parameters: {
+    docs: {
+      page: () => <Page />,
+    },
+  },
+} satisfies Meta<typeof PopoutRestoreStory>;
+
+export default meta;
+type Story = StoryObj<typeof meta>;
+
+/** Steps to reproduce AB#2024472:
+ * 1. Pop the widget out (drag its tab out of the panel, or use the tab's
+ *    "..." menu and click "Pop out active widget tab").
+ * 2. Click "Hide widget".
+ * 3. Click "Show widget".
+ *
+ * Expected: the widget re-appears in its popout window.
+ * Before the fix it would instead dock back into the left panel.
+ */
+export const Default: Story = {};
diff --git a/docs/storybook/src/widget/PopoutRestore.tsx b/docs/storybook/src/widget/PopoutRestore.tsx
new file mode 100644
index 00000000000..3f3ddaec0be
--- /dev/null
+++ b/docs/storybook/src/widget/PopoutRestore.tsx
@@ -0,0 +1,90 @@
+/*---------------------------------------------------------------------------------------------
+ * Copyright (c) Bentley Systems, Incorporated. All rights reserved.
+ * See LICENSE.md in the project root for license terms and full copyright notice.
+ *--------------------------------------------------------------------------------------------*/
+import React from "react";
+import {
+  StagePanelState,
+  UiItemsProvider,
+  WidgetState,
+  useSpecificWidgetDef,
+} from "@itwin/appui-react";
+import { Button } from "@itwin/itwinui-react";
+import { AppUiStory } from "../AppUiStory";
+import { createFrontstage, createWidget } from "../Utils";
+
+/** Demonstrates that a popped-out widget remains popped out after being hidden
+ * (e.g. because it has no content to display) and then shown again.
+ *
+ * The hide/show controls live outside of the widget (as `AppUiStory` children)
+ * since hiding the widget unmounts its content, which would otherwise take the
+ * "Show widget" button down with it.
+ *
+ * To reproduce: pop the widget out (drag its tab out, or use the "..." menu),
+ * then click "Hide widget" and "Show widget". Before the fix (AB#2024472) the
+ * widget would dock back into the panel instead of staying popped out.
+ */
+export function PopoutRestoreStory() {
+  const provider = {
+    id: "widgets",
+    getWidgets: () => [
+      createWidget(1, {
+        canPopout: true,
+        content: <div style={{ padding: "0.5em" }}>Widget content</div>,
+      }),
+    ],
+  } satisfies UiItemsProvider;
+  return (
+    <AppUiStory
+      itemProviders={[provider]}
+      frontstages={[
+        createFrontstage({
+          leftPanelProps: {
+            defaultState: StagePanelState.Open,
+          },
+        }),
+      ]}
+    >
+      <WidgetVisibilityControls />
+    </AppUiStory>
+  );
+}
+
+function WidgetVisibilityControls() {
+  const widgetDef = useSpecificWidgetDef("w1");
+  const [visible, setVisible] = React.useState(true);
+
+  const hide = () => {
+    setVisible(false);
+    widgetDef?.setWidgetState(WidgetState.Hidden);
+  };
+  const show = () => {
+    setVisible(true);
+    widgetDef?.setWidgetState(WidgetState.Open);
+  };
+
+  return (
+    <div
+      style={{
+        position: "absolute",
+        bottom: 0,
+        left: 0,
+        zIndex: 1000,
+        padding: "0.5em",
+        display: "flex",
+        flexDirection: "column",
+        gap: "0.5em",
+      }}
+    >
+      <div>Widget state: {visible ? "Visible" : "Hidden"}</div>
+      <div style={{ display: "flex", gap: "0.5em" }}>
+        <Button onClick={hide} size="small">
+          Hide widget
+        </Button>
+        <Button onClick={show} styleType="cta" size="small">
+          Show widget
+        </Button>
+      </div>
+    </div>
+  );
+}
diff --git a/ui/appui-react/src/appui-react/frontstage/FrontstageDef.tsx b/ui/appui-react/src/appui-react/frontstage/FrontstageDef.tsx
index 3e00e605d94..84c52ec1c23 100644
--- a/ui/appui-react/src/appui-react/frontstage/FrontstageDef.tsx
+++ b/ui/appui-react/src/appui-react/frontstage/FrontstageDef.tsx
@@ -63,6 +63,7 @@ import {
   FRONTSTAGE_SETTINGS_NAMESPACE,
   getFrontstageStateSettingName,
 } from "../widget-panels/Frontstage.js";
+import { MIN_POPOUT_WINDOW_SIZE } from "../layout/state/WidgetRestoreState.js";
 
 /** FrontstageDef class provides an API for a Frontstage.
  * @public
@@ -746,8 +747,8 @@ export class FrontstageDef {
     const popoutWidget = state.popoutWidgets.byId[location.popoutWidgetId];
     const bounds = Rectangle.create(popoutWidget.bounds);
     const position: ChildWindowLocationProps = {
-      width: bounds.getWidth(),
-      height: bounds.getHeight(),
+      width: Math.max(bounds.getWidth(), MIN_POPOUT_WINDOW_SIZE.width),
+      height: Math.max(bounds.getHeight(), MIN_POPOUT_WINDOW_SIZE.height),
       left: bounds.left,
       top: bounds.top,
     };
@@ -764,9 +765,11 @@ export class FrontstageDef {
     // Use outer size if available to avoid inner size + browser zoom issues: https://github.com/iTwin/appui/issues/563
     const savedTab = state.savedTabs.byId[tabId];
     if (childWindow && savedTab?.popout?.size) {
+      // Enforce a minimum size so a popout window that shrunk over repeated pop-out cycles
+      // can never become invisible or unusable.
       childWindow.resizeTo(
-        savedTab.popout.size.width,
-        savedTab.popout.size.height
+        Math.max(savedTab.popout.size.width, MIN_POPOUT_WINDOW_SIZE.width),
+        Math.max(savedTab.popout.size.height, MIN_POPOUT_WINDOW_SIZE.height)
       );
     }
 
diff --git a/ui/appui-react/src/appui-react/layout/state/NineZoneStateReducer.ts b/ui/appui-react/src/appui-react/layout/state/NineZoneStateReducer.ts
index 487316b6306..2968e8abb08 100644
--- a/ui/appui-react/src/appui-react/layout/state/NineZoneStateReducer.ts
+++ b/ui/appui-react/src/appui-react/layout/state/NineZoneStateReducer.ts
@@ -75,6 +75,7 @@ import {
 import { getUniqueId } from "../base/NineZone.js";
 import {
   isPanelWidgetRestoreState,
+  MIN_POPOUT_WINDOW_SIZE,
   type PanelWidgetRestoreState,
 } from "./WidgetRestoreState.js";
 import {
@@ -670,6 +671,25 @@ export function NineZoneStateReducer(
       if (size) preferredBounds = preferredBounds.setSize(size);
       if (position) preferredBounds = preferredBounds.setPosition(position);
 
+      // Enforce a minimum size so a popout window can never shrink to an invisible or
+      // unusable size across repeated pop-out cycles (see AB#2024472). Matches the
+      // minimum size used for floating widgets (see `minWidth`/`minHeight` in `Widget.tsx`).
+      if (
+        preferredBounds.getWidth() < MIN_POPOUT_WINDOW_SIZE.width ||
+        preferredBounds.getHeight() < MIN_POPOUT_WINDOW_SIZE.height
+      ) {
+        preferredBounds = preferredBounds.setSize({
+          width: Math.max(
+            preferredBounds.getWidth(),
+            MIN_POPOUT_WINDOW_SIZE.width
+          ),
+          height: Math.max(
+            preferredBounds.getHeight(),
+            MIN_POPOUT_WINDOW_SIZE.height
+          ),
+        });
+      }
+
       const popoutWidgetId = getUniqueId();
       let home: PopoutWidgetState["home"] | undefined;
       if (location && isPanelTabLocation(location)) {
@@ -1032,6 +1052,15 @@ function hideTab(state: NineZoneState, id: TabState["id"]) {
         floatingWidget,
       };
     });
+  } else if (isPopoutTabLocation(location)) {
+    const popoutWidget = state.popoutWidgets.byId[widgetId];
+    state = updateSavedTabState(state, id, (draft) => {
+      draft.home = {
+        widgetId,
+        tabIndex,
+        popoutWidget,
+      };
+    });
   } else if (isPanelTabLocation(location)) {
     const side = location.side;
     const widgetIndex = state.panels[side].widgets.indexOf(widgetId);
diff --git a/ui/appui-react/src/appui-react/layout/state/SavedTabState.ts b/ui/appui-react/src/appui-react/layout/state/SavedTabState.ts
index f096aec9de3..b479626de0a 100644
--- a/ui/appui-react/src/appui-react/layout/state/SavedTabState.ts
+++ b/ui/appui-react/src/appui-react/layout/state/SavedTabState.ts
@@ -8,11 +8,11 @@
 
 import type { XAndY } from "@itwin/core-geometry";
 import type { TabState } from "./TabState.js";
-import type { WidgetRestoreState } from "./WidgetRestoreState.js";
+import type { TabRestoreState } from "./WidgetRestoreState.js";
 import type { SizeProps } from "../../utils/SizeProps.js";
 
 /** @internal */
-export type TabHomeState = WidgetRestoreState & {
+export type TabHomeState = TabRestoreState & {
   readonly tabIndex: number;
 };
 
diff --git a/ui/appui-react/src/appui-react/layout/state/WidgetRestoreState.ts b/ui/appui-react/src/appui-react/layout/state/WidgetRestoreState.ts
index 6556daa4116..8897a9ee7c5 100644
--- a/ui/appui-react/src/appui-react/layout/state/WidgetRestoreState.ts
+++ b/ui/appui-react/src/appui-react/layout/state/WidgetRestoreState.ts
@@ -7,7 +7,18 @@
  */
 
 import type { PanelSide } from "../widget-panels/PanelTypes.js";
-import type { FloatingWidgetState, WidgetState } from "./WidgetState.js";
+import type { SizeProps } from "../../utils/SizeProps.js";
+import type {
+  FloatingWidgetState,
+  PopoutWidgetState,
+  WidgetState,
+} from "./WidgetState.js";
+
+/** Minimum size enforced for a popped-out widget window. */
+export const MIN_POPOUT_WINDOW_SIZE: SizeProps = {
+  width: 200,
+  height: 200,
+};
 
 /** @internal */
 export interface FloatingWidgetRestoreState {
@@ -15,6 +26,12 @@ export interface FloatingWidgetRestoreState {
   floatingWidget: FloatingWidgetState;
 }
 
+/** @internal */
+export interface PopoutWidgetRestoreState {
+  widgetId: WidgetState["id"];
+  popoutWidget: PopoutWidgetState;
+}
+
 /** @internal */
 export interface PanelWidgetRestoreState {
   widgetId: WidgetState["id"];
@@ -27,16 +44,29 @@ export type WidgetRestoreState =
   | FloatingWidgetRestoreState
   | PanelWidgetRestoreState;
 
+/** Restore state for a tab, which (unlike {@link WidgetRestoreState}) can also
+ * restore into a popout window.
+ * @internal
+ */
+export type TabRestoreState = WidgetRestoreState | PopoutWidgetRestoreState;
+
 /** @internal */
 export function isFloatingWidgetRestoreState(
-  state: WidgetRestoreState
+  state: TabRestoreState
 ): state is FloatingWidgetRestoreState {
   return "floatingWidget" in state;
 }
 
+/** @internal */
+export function isPopoutWidgetRestoreState(
+  state: TabRestoreState
+): state is PopoutWidgetRestoreState {
+  return "popoutWidget" in state;
+}
+
 /** @internal */
 export function isPanelWidgetRestoreState(
-  state: WidgetRestoreState
+  state: TabRestoreState
 ): state is PanelWidgetRestoreState {
   return "side" in state;
 }
diff --git a/ui/appui-react/src/appui-react/layout/state/internal/TabStateHelpers.ts b/ui/appui-react/src/appui-react/layout/state/internal/TabStateHelpers.ts
index dac93b85b99..30967f8b399 100644
--- a/ui/appui-react/src/appui-react/layout/state/internal/TabStateHelpers.ts
+++ b/ui/appui-react/src/appui-react/layout/state/internal/TabStateHelpers.ts
@@ -16,6 +16,7 @@ import type { SavedTabState, TabHomeState } from "../SavedTabState.js";
 import { getTabLocation } from "../TabLocation.js";
 import {
   addFloatingWidget,
+  addPopoutWidget,
   assertWidgetState,
   getWidgetState,
   removeWidget,
@@ -23,7 +24,10 @@ import {
   updateWidgetState,
 } from "./WidgetStateHelpers.js";
 import type { WidgetState } from "../WidgetState.js";
-import { isFloatingWidgetRestoreState } from "../WidgetRestoreState.js";
+import {
+  isFloatingWidgetRestoreState,
+  isPopoutWidgetRestoreState,
+} from "../WidgetRestoreState.js";
 import { Rectangle } from "@itwin/core-react/internal";
 import { getUniqueId } from "../../base/NineZone.js";
 import { insertPanelWidget } from "./PanelStateHelpers.js";
@@ -231,6 +235,13 @@ export function addRemovedTab(
     });
   }
 
+  // Add to a popout widget (i.e. re-open its child window).
+  if (isPopoutWidgetRestoreState(home)) {
+    return addPopoutWidget(state, widgetId, [tabId], {
+      ...home.popoutWidget,
+    });
+  }
+
   // Add to a panel section.
   const panel = state.panels[home.side];
 
diff --git a/ui/appui-react/src/test/frontstage/FrontstageDef.test.tsx b/ui/appui-react/src/test/frontstage/FrontstageDef.test.tsx
index 885d93b5ac9..50f63ef8e41 100644
--- a/ui/appui-react/src/test/frontstage/FrontstageDef.test.tsx
+++ b/ui/appui-react/src/test/frontstage/FrontstageDef.test.tsx
@@ -699,6 +699,44 @@ describe("FrontstageDef", () => {
       );
       expect(spy).toHaveBeenCalledOnce();
     });
+
+    it("should enforce a minimum popout window size (AB#2024472)", async () => {
+      const frontstageDef = new FrontstageDef();
+      await frontstageDef.initializeFromConfig({
+        ...defaultFrontstageConfig,
+        leftPanel: {
+          sections: {
+            start: [
+              {
+                id: "t1",
+              },
+            ],
+          },
+        },
+      });
+      initializeNineZoneState(frontstageDef);
+
+      const spy = vi.spyOn(window, "open").mockReturnValue({
+        addEventListener: () => {},
+        removeEventListener: () => {},
+      } as unknown as Window);
+      frontstageDef.popoutWidget("t1", undefined, {
+        width: 10,
+        height: 10,
+      });
+
+      spy.mockReset();
+      const popoutWidgets = frontstageDef.nineZoneState!.popoutWidgets;
+      const popoutWidget = popoutWidgets.byId[popoutWidgets.allIds[0]];
+      frontstageDef.openPopoutWidgetContainer(
+        popoutWidget.id,
+        frontstageDef.nineZoneState
+      );
+      expect(spy).toHaveBeenCalledOnce();
+      const features = spy.mock.calls[0][2] as string;
+      expect(features).to.include("width=200");
+      expect(features).to.include("height=200");
+    });
   });
 
   describe("dockWidgetContainer", () => {
diff --git a/ui/appui-react/src/test/layout/state/NineZoneStateReducer.test.ts b/ui/appui-react/src/test/layout/state/NineZoneStateReducer.test.ts
index b5bffcf03b2..70908e8c3ed 100644
--- a/ui/appui-react/src/test/layout/state/NineZoneStateReducer.test.ts
+++ b/ui/appui-react/src/test/layout/state/NineZoneStateReducer.test.ts
@@ -29,6 +29,8 @@ import {
   updateSavedTabState,
 } from "../../../appui-react/layout/state/internal/TabStateHelpers.js";
 import { getUniqueId } from "../../../appui-react/layout/base/NineZone.js";
+import { getTabLocation } from "../../../appui-react/layout/state/TabLocation.js";
+import type { PopoutWidgetRestoreState } from "../../../appui-react/layout/state/WidgetRestoreState.js";
 
 describe("NineZoneStateReducer", () => {
   it("should not update for unhandled action", () => {
@@ -1686,6 +1688,41 @@ describe("NineZoneStateReducer", () => {
       });
     });
 
+    it("should enforce a minimum size when saved bounds are too small", () => {
+      let state = createNineZoneState({
+        savedTabs: {
+          allIds: ["t1"],
+          byId: {
+            t1: {
+              id: "t1",
+              popout: {
+                position: {
+                  x: 20,
+                  y: 10,
+                },
+                contentSize: {
+                  height: 40,
+                  width: 30,
+                },
+              },
+            },
+          },
+        },
+      });
+      state = addTabs(state, ["t1"]);
+      state = addPanelWidget(state, "right", "rightStart", ["t1"]);
+
+      const newState = NineZoneStateReducer(state, {
+        type: "WIDGET_TAB_POPOUT",
+        id: "t1",
+      });
+      const popoutWidgetId = newState.popoutWidgets.allIds[0];
+      const popoutWidget = newState.popoutWidgets.byId[popoutWidgetId];
+      const bounds = Rectangle.create(popoutWidget.bounds);
+      expect(bounds.getWidth()).to.be.gte(200);
+      expect(bounds.getHeight()).to.be.gte(200);
+    });
+
     it("should popout with default size and location", () => {
       let state = createNineZoneState({ size: { height: 1000, width: 1600 } });
       state = addTabs(state, ["t1"]);
@@ -1704,7 +1741,7 @@ describe("NineZoneStateReducer", () => {
       });
     });
 
-    it("should popout with specified size and location", () => {
+    it("should popout with specified size and location (clamped to minimum width)", () => {
       let state = createNineZoneState({ size: { height: 1000, width: 1600 } });
       state = addTabs(state, ["t1", "ta", "tb"]);
       state = addPanelWidget(state, "right", "rightStart", ["t1", "ta", "tb"], {
@@ -1725,11 +1762,13 @@ describe("NineZoneStateReducer", () => {
       });
       expect(newState.popoutWidgets.allIds).lengthOf(1);
       const popoutWidgetId = newState.popoutWidgets.allIds[0];
+      // Requested width (100) is below the minimum popout window size and gets clamped to
+      // 200 (AB#2024472); height (200) is already at the minimum.
       expect(newState.popoutWidgets.byId[popoutWidgetId].bounds).toEqual({
         left: 5,
         top: 10,
         bottom: 10 + 200,
-        right: 5 + 100,
+        right: 5 + 200,
       });
     });
 
@@ -1812,7 +1851,7 @@ describe("NineZoneStateReducer", () => {
       });
     });
 
-    it("should popout a tab and fit to preferredFloatingWidgetSize if bounds are not set", () => {
+    it("should popout a tab and fit to preferredFloatingWidgetSize if bounds are not set (clamped to minimum size)", () => {
       let state = createNineZoneState();
       state = addTab(state, "t1", {
         preferredFloatingWidgetSize: { width: 50, height: 50 },
@@ -1825,15 +1864,16 @@ describe("NineZoneStateReducer", () => {
       });
       expect(newState.popoutWidgets.allIds).toHaveLength(1);
       const popoutWidgetId = newState.popoutWidgets.allIds[0];
+      // A preferred size smaller than the minimum popout window size is clamped up (AB#2024472).
       expect(newState.popoutWidgets.byId[popoutWidgetId].bounds).toEqual({
         left: 0,
         top: 0,
-        bottom: 50,
-        right: 50,
+        bottom: 200,
+        right: 200,
       });
     });
 
-    it("should popout a tab and fit to content container if preferredFloatingWidgetSize is not set", () => {
+    it("should popout a tab and fit to content container if preferredFloatingWidgetSize is not set (clamped to minimum size)", () => {
       let state = createNineZoneState();
 
       const blankHTML = document.createElement("div");
@@ -1850,11 +1890,13 @@ describe("NineZoneStateReducer", () => {
       expect(newState.popoutWidgets.allIds).toHaveLength(1);
       const popoutWidgetId = newState.popoutWidgets.allIds[0];
 
+      // A blank content container measures 20x20 but gets clamped to the minimum popout
+      // window size (AB#2024472).
       expect(newState.popoutWidgets.byId[popoutWidgetId].bounds).toEqual({
         left: 0,
         top: 0,
-        bottom: 20,
-        right: 20,
+        bottom: 200,
+        right: 200,
       });
     });
   });
@@ -1941,7 +1983,7 @@ describe("NineZoneStateReducer", () => {
       });
     });
 
-    it("should hide tab in a popout widget", () => {
+    it("should hide tab in a popout widget and remember its popout home", () => {
       let state = createNineZoneState();
       state = addTab(state, "t1");
       state = addPopoutWidget(state, "w1", ["t1"]);
@@ -1951,7 +1993,35 @@ describe("NineZoneStateReducer", () => {
         id: "t1",
       });
       expect(newState.popoutWidgets.allIds).lengthOf(0);
-      expect(newState.savedTabs.byId.t1).toEqual(undefined);
+      expect(newState.savedTabs.byId.t1?.home).to.deep.include({
+        widgetId: "w1",
+        tabIndex: 0,
+      });
+      expect(
+        (newState.savedTabs.byId.t1?.home as PopoutWidgetRestoreState)
+          .popoutWidget.id
+      ).to.eq("w1");
+    });
+
+    it("should restore a hidden tab back into a popout widget when shown", () => {
+      let state = createNineZoneState();
+      state = addTab(state, "t1");
+      state = addPopoutWidget(state, "w1", ["t1"]);
+      state = NineZoneStateReducer(state, {
+        type: "WIDGET_TAB_HIDE",
+        id: "t1",
+      });
+      expect(state.popoutWidgets.allIds).lengthOf(0);
+
+      const newState = NineZoneStateReducer(state, {
+        type: "WIDGET_TAB_OPEN",
+        id: "t1",
+      });
+      expect(newState.popoutWidgets.allIds).lengthOf(1);
+      expect(getTabLocation(newState, "t1")).to.deep.eq({
+        widgetId: newState.popoutWidgets.allIds[0],
+        popoutWidgetId: newState.popoutWidgets.allIds[0],
+      });
     });
 
     it("should return correct index for first tab", () => {