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Lightweight materials and lightweight technologies gained significant attention from all EV vehicle manufacturers. Aluminium has been commonly used as a lightweight replacement for steel in the automotive industry for many years. High-strength aluminium alloys have high specific strength, and their formability increases significantly at elevated temperatures. New manufacturing technologies incorporating elevated temperature forming have emerged recently, allowing forming of high and ultrahigh-strength aluminium alloys. One such technology is HFQ® which is a process that combines high formability with virtually no springback for (ultra)-high-strength aluminium alloys. The thermal expansion of aluminium alloys is approximately twice that of steel, leading to significant material contraction during in-die quenching. This is especially pronounced for large or long components. Therefore, robustness analysis of the process parameters can be used to optimise the process parameters and enable a capable production of parts meeting dimensional specification requirements. Such analysis can be performed using AutoForm-Sigma solver and this paper presents a simulation methodology developed in AutoForm and its use to verify the accuracy of the thermal distortion prediction for one of the safety cell structure components. Sigma simulation has been implemented to optimise the process parameters to improve manufacturing robustness.