References
The well-known report about Umar bin Khattab's conversion to Islam shows that large passages of the Qur'an had already been written down even at the early time, in Mecca, long before the hijra, when the Prophet was still in the house of Arqam (one of the first converts in Islam). It was surah Taha (chapter 20) of the Qur'an which Umar read in the sheet of his sister that brought him to Islam. – [Ibn Hisham, pp.156-157]
One of the scribes of the Prophet, Zaid bin Thabit is said: “'We used to compile the Qur'an from small scraps in the presence of the Apostle.” – [Suyuti, Itqan, I, p. 99; Salih, Mabahith fi ‘ulum al-Qur’an, p.69.]
When surah 4 verse 95 of the Qur'an was revealed, the Prophet said: "Call Zaid for me, let him bring the board, the ink pot, and the scapula bones." Then he said to him: "Write: 'Not equal are those believers...' (4:95) – [Bukhari, VI, No.512; also VI, No.116- 118]
It was also reported that material upon which the revelation had been written down was kept in the house of the Prophet. – [Suyuti, Itqan, I, p.58]
Another report informs us that when people came to Madina to learn about Islam in the time of the Prophet, they were provided with copies of the chapters of the Qur'an, to read and learn them by heart. – [Hamidullah M., Sahifa Hammam ibn Munabbih, p.64]
The Qur'an did exist as a written document in the life time of the Prophet, as mentioned in the following record: The Prophet said: "Do not take the Qur'an on a journey with you, for I am afraid lest it should fall into the hands of the enemy (i.e. the enemy may seize it and may quarrel with you over it)”. – [Muslim, III, No.4607,4608,4609; Bukhari, IV, No.233]
One of the Prophet’s companions, Ibn Umar, said: “No doubt the Prophet and his Companions traveled in the land of the enemy and they knew the Qur'an then (i.e. that the Qur'an was carried as a written scripture, by the Muslims)” – [ Bukhari, IV, p. 146, Ch.129]
The Prophet sent copies of the chapters of the Qur'an with some Muslims for instruction in Islam to the people of Yemen. – [Muwatta' Imam Malik, p.204]
During Prophet’s last pilgrimage, at the sermon which he gave to the large gathering of Muslims, the Prophet said: “I have left with you something which if you will hold fast to it you will never fall into error, a plain indication, The Book of God....” – [Ibn Hisham, p. 651.]

Uthman instructed Zaid together with three other sahabah (Companions) to prepare copies from the suhuf kept with Hafsa.

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