The automotive and aerospace industries have increasingly relied on Finite Element (FE) simulations to optimize their forming processes and reduce the costs and time associated with physical prototyping. However, ensuring the accuracy of these simulations in predicting actual forming defects remains a critical concern. To address this issue, a comprehensive convergence analysis, meticulously conducted, systematically compares the induced forming defects in FE-based simulations, point cloud representations, and actual formed parts. The study involves utilizing FE simulations to model various forming processes, capturing intricate details of formability, material-tool interactions, and varying key simulation parameters, such as material and process parameters. The study aimed to assess the sensitivity of the FE simulations to these parameters and to identify convergence criteria that lead to results closely resembling the actual formed parts and point cloud data. To achieve this, convergence studies were conducted to systematically vary these parameters and compare the simulated results against point cloud data obtained through advanced scanning technologies, providing a high-fidelity representation of the formed components. The study’s comparative analysis included a detailed examination of common forming defects such as wrinkles, bridging, and gaps, employing quantitative metrics to measure the deviation between the simulated, scanned, and actual formed parts.