Word to this and a bunch of other posts from Joe and the prestige on this. Seems simple that not having real guns on set would be simpler, safer and cheaper.
All these perspectives don't really take account of the business of filmmaking. When I asked an armourer about this a few years ago the answer was a lot more mundane that what gets put forward here.
It really isn't about achieving any particular fetishistic shot of a gun. Any shot can be faked. If there's a shot of somebody loading a gun, pointing it at someone and shooting them, it can be faked, even in a student movie. Everybody knows that, a little ingenuity is all it takes. One of the things folks here don't account for is that, the crew are not just getting a shot, they're trying to make a whole movie, with less time and money than they'd like. If there's guns throughout the movie, they can't plan every scene, they can't pause for ingenuity every time there's a new idea. They need a general, one-size-fits-all solution to their guns that they can use every day.
For the armourer, supplying guns to a movie set is a business, and a competitive one in a small industry. The challenge for the armourer is to provide a professional service, which means catering to a wide range of needs, anticipating improvisation, managing spikes in demand, supplying on time at short notice, and supplying high quality, close-up ready, functioning props. What he told me, and another later agreed with, is that the supply chain for replicas and deactivated weapons isn't robust enough and that it's quite simply easier to get real ones
sometimes. What he added, is that it's not even viable to build a robust supply chain because the demand is so erratic.
What's quite frustrating while reading these threads is to see the industry dismissed as stupid, and all kinds of ideas put forward, but the industry was already doing all of them. Armourers can make plastic moulded replicas for BG artists quite quickly and easily. They do that a lot (from real guns). They use BB guns, which have been a godsend, because there's a great supply chain of those, especially for modern guns. They use movie-specific devices which can simulate gunfire without any propellant.
For the VFX solution, pretty much everyone who has commented here has it wrong. Producers, directors, ADs, actors, love the VFX solution because it makes the working days much faster. No reloads, no earplugs, no waiting for the smoke to clear between takes. But outside of certain easy scenarios it's still very expensive. HGR's pay for the entire movie would not cover the cost of unloading a six shooter in one scene. And you'd still have to pay HGR.
So while there's not a compelling single reason to use a real gun in any one scene, the safety aspect isn't really compelling enough to completely eliminate the last few guns from the industry. The last few guns are the hardest to get rid of, but also should be the easiest to manage. The negligence on the set of Rust was staggering. The safety protocols are really not difficult, any average person could have performed them. This is likely why we've not seen much in the way of an industry ban, even as we continue to see a dramatic reduction.