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True.. Ease of manufacture could influence or dictate style...I'm gonna add another guess as to why round vs octagon. It's tough to make a nice uniform round cylinder without a lathe as opposed to draw filing flats with a simple file and a lot of patience. Lathe turning on the other hand would make for faster production given the proper equipment.
Yet most* military arms of the time had round barrels or at the most were octagon only at the breech...so I am still leaning to style , price point and what sold well...
*The 1803 models of the "Harper's Ferry" rifle with its half round / half octagon barrel come to mind as an exception here...
The half round / half octagon barrel was also popular in many sporting firearms , both rifled and smooth bore during this period
Andy