You're all right that safety isn't just an option anymore, and it seems like manufacturers are well aware of this fact and supporting this trend. Rockwell also just came out with some tools to help engineers navigate safety as they are designing machines: http://www.designnews.com/document.asp?doc_id=262277
A make-your-own Star Wars Sith Lightsaber hilt is heftier and better-looking than most others out there, according to its maker, Sean Charlesworth. You can 3D print it from free source files, and there's even a hardware kit available -- not free -- so you can build one just in time for Halloween.
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