There's no reason to ever use live rounds, even 'blanks' on a set. While accidents of this nature on set are rare, they shouldn't be occurring at all. This move to using CGI to portray muzzle flashes is the safest and smartest route and I hope to see more movie and tv productions take this route.
ABC’s ‘The Rookie’ Bans “Live” Guns on Set
The change, effective Friday, comes in the wake of the fatal shooting on the set of Alec Baldwin's 'Rust.'
The misfires alone should have been a HUGE red flag.
The crew complaints about unsafe working conditions is another.
They should have replaced the gun and addressed the crew concerns. Instead, they replaced the crew & kept the gun.