I think that when we view anything from the early days of this country, and ask “did they” do this, or that, the first thing you need to define is who was the “they”. America had to deal with the remnants of the social status system that controlled virtually all of Europe. It didn’t break down over night. So a farmer on the frontier didn’t do thing the same way as a gentleman in the city, or a plantation owner in the South did. I would imagine men of some social standing, likely had pre- cut patches in their patchboxes. But, we know those of lesser statis especially in the South didn’t use pre-cut patches much because many of the guns they used had no patch box.
I know for a fact that in the early twentieth century in the rural Midwest, folks cut patches at the muzzle. When I first started shooting a muzzleloader, my grandfather mentioned that the only whipping he ever got from his mother ( who he adored) was for cutting bullet patches out of his shirttail.
Hungry Horse