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Insecticide resistance poses a significant challenge in managing generalist herbivores such as the tobacco cutworm (TCW), Spodoptera litura. This study investigates the potential risks associated with using the novel diamide insecticide tetraniliprole to control TCW. A tetraniliprole-resistant strain was developed through twelve generations of laboratory selection, indicating an intermediate risk of resistance development. Field monitoring in China revealed a significant incidence of resistance, particularly in the Nanchang (NC) population (>100-fold). Tetraniliprole showed moderate to high cross-resistance to multiple insecticides and was autosomally inherited with incomplete dominance, controlled by multiple genes, some of which belong to the cytochrome P450 family associated with enhanced detoxification. Life table studies indicated transgenerational hormesis, stimulating TCW female fecundity and increasing population net reproduction rates (R 0). These findings suggest a potential for pest resurgence under tetraniliprole use. The integrated risk assessment provides a basis for the sustainable management of TCW using tetraniliprole. [Display omitted] • The likelihood of tetraniliprole resistance was assessed in Spodoptera litura. • High cross-resistance between tetraniliprole and other insecticides was recorded. • Tetraniliprole resistance in S. litura was autosomal, polygenic, and incompletely dominant. • Low tetraniliprole concentrations stimulated female fecundity in S. litura. • Tetraniliprole-induced hormesis poses high resurgence risk for S. litura. [ABSTRACT FROM AUTHOR]