Not to be overly blunt about it, but anyone playing who can't pick up a weapon in the dark, blindfolded, or otherwise blinded, and can't tell the difference between a toobstick and a flatblade in 1.5 seconds shouldn't be playing. It's called "Grab the blade, what shape/texture is it. Oh, it's that kind. Never mind then." I don't think we have anyone currently playing that falls into that category, and anyone who shows up that does should be pulled aside and 'splained to, or pulled aside and asked not to play. I know people have concerns, and I'm not saying their completely unjustified, but really it IS a contact sport and people will play/fight to the level of gear we use. I see maybe one hold an event from an errant thrust of a weapon, but probably half a dozen step backs from packets to the eye/throat/junk, but no one has ever argued the safety of spell packets, even when they turn to cement in the puddles.
I think we have some very talented weapon crafters out here on the WC: Matt, JP, and Sarah just to name the ones that I know people order weapons from regularly. I feel quite certain that those three and some others who don't do as much publically could easily come up with ways to make flatblade weapons, latex or non-, that people could feel comfortable with, and then put down instructions for making said weapons in a way that most people could follow, just like they do with regular boffers. I for one would really like to see that, along with a look at dumbing down the safety factor on thrown weapons. Ye gods we could make some daggers that won't hurt but are smaller than a zucchini!