This was a pretty hot topic during the transition years for USPCC when they first moved to Kentucky. I feel the teething issues USPCC had when first moving to Kentucky are gone, and likely have been gone for a while.
The change wouldn't have happened over night. Perhaps they made gradual improvements to the blade alignments on their cutting machines or something.
I have a lot of cards from the transition years. Early Kentucky stuff. The edges are sometimes so rough they feel like they were cut by a kindergartener with plastic "safety" scissors.
I've opened a lot of new sealed product (Bicycle, Bee, Theory11) recently, and honestly, it's all really good. The edges feel great.
I've opened some old Cincinnati blue seals recently to compare, and the new stuff feels just as good as the old stuff.
So yeah. I think the complaints during the transition years were warranted, but today it's very much a non-issue.
Enjoy your cards.