> I'm sure you could make a metal sword which has blunt edges and a soft point.

Most acting swords are safe in the cut. That's rarely a problem.

The real problem is the thrust. In order for a sword to move like a sword, it needs to be stiff.

Most fencing/acting swords have blunt/rounded tips, but that doesn't really matter if you get stabbed in the face - there's just too much force over too little surface area and some facial bones are too weak. In order to be truly safe without a fencing mask, the tip would have to be unacceptably large.