Strange problem with many search engine hits around documents created via MS forms through Power Automate to SharePoint online but not finding one explaining what could cause this phenomenon...
The short story: have created a MS form that the user can select various options which would populate the "quick part" field in a MS word template stored in SharePoint and create a new document which the user can either download or edit directly from SharePoint using client Word app.
Document gets created in SharePoint, when I display the document details in SharePoint, I can see all the fields are populated, if I turn on the view in SharePoint to display the columns, I can see the data is also there. I then open the document in the client word app and all I see are the quick part field definitions. If I navigate to the File>Info>Show Properties I see the metadata from SharePoint, If I open the SharePoint Properties panel View>SharePoint I also see the metadata....
However, the client application shows this error message:

The created document shows the quick parts fields but not the data

The SharePoint properties panel in client app shows the data is there

The document properties portion of the same panel (which I assume are the standard document library fields and not required for the document)

The client app Info properties panel also shows the metadata with only one field (a multiline plain text field) that has a red block around it, not quite sure why as the data is only 365 characters and there are other multline columns that have more data in them ...


The same column in SharePoint defined as:

and SharePoint Properties panel of the document also shows the relevant data...

None of the columns / fields are defined as "required" all are defined as "optional", so why would the data not populate the document? Any pointers as to what causes this would be great!
PS: I already checked that there are no policies on being applied to SharePoint, the "DIP" settings are checked for the document library

Any ideas or pointers as to how to fix this?