A novel flexible roll forming method, which is a complex process of repetitive loading, was proposed for manufacturing large curved and thinwalled metal plates. Edge wave is one of the significant defects in flexible roll forming due to its complex forming variables. A finite element model was established to analyze the effect of main forming variables, such as forming path, the number of forming stations and the distance between stations, on edge wave in flexible roll forming. The simulation results show that forming path has a great influence on edge wave. The increase of the number of roll stations and the distance between roll stations could result in reducing edge wave.