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Classic example of poor/ lack of regulation in USA. (Mah freedum)
Obviously a prop weapon shouldn't even be able to shoot real bullets.
This can easily be accomplished by making the prop weapon 1mm smaller, so real bullets can't even be inserted.
To tell them apart the prop ammo could have a slightly toned line in the length of the bullet, which would be hard to see on film, because it look like a reflection, and could even be pointed away when filming. But would be easy to detect when holding the bullet, because the reflection wouldn't move right when you hold it. It would work kind of like a watermark on bills.
Why the movie industry hasn't implemented better security themselves IDK, except the obvious, not doing it is slightly cheaper. Except the easier positive identification of a prop, would probably make for a smoother work flow, so even if the equipment is a bit more expensive, it would be recouped by smoother workflow, and zero accidents.
But by far the easiest and cheapest solution is a federal law, because that would standardize it for all.
I know a guy who teaches stage combat for live theater and have seen him on more than one occasion talk directors out of using prop firearms that fire blanks (think something akin to a starters pistol). These guns have filled barrels, etc. so there’s no way they could ever fire an actual projectile.
One of the huge problems with these sorts of guns is that they’re very prone to misfiring. For whatever reason the manufacturing quality of both starter guns and the blanks they use just isn’t as good as real firearms. The last thing you want in live theater (which I’ve seen more than once) is for an actor to pull the trigger and hear a click instead of a bang.
Granted they could just re-shoot a movie scene if this happens, but that costs time & money, which they absolutely hate wasting.
Your idea of using smaller caliber bores, etc. likely wouldn’t prevent this sort of thing because either the quality would again suffer due to the lack of demand, or some idiot would still produce real ammo for it, or at least a projectile firing blank.
Movies like Rust use revolvers because that’s what cowboys would have used. They want the guns to look real, which means the cylinder should look like it has real bullets in them and not blanks, especially in close-up shots where you can clearly see a gun. That’s ultimately what killed Brandon Lee on his movie set. The special effects team botched rigging the bullets so they wouldn’t fire. They removed the powder but didn’t remove the primer cap, and at close range that was still enough to cause trauma when Lee was shot.
I also know a guy with 40+ years in the movie special effects industry who actually writes OSHA safety regulations for the industry. They’re “written in blood” due to events like Brandon Lees death, and when followed properly everybody is safe. He wasn’t involved in any way with the Rust production, but he was extremely pissed when he started hearing what’s been reported. He said it sounds like pretty much everybody involved from the producer on down ignored those regulations, and he had no problem with folks like Baldwin facing charges as a result.
Minor nitpick: the primer in the botched dummy cartridge wasn't enough to fire the bullet, but it was enough to unseat to it from the case and lodge it in the barrel. Later, a normal blank cartridge was fired while the bullet was still stuck in the barrel. The powder in the blank was enough to dislodge the bullet and propel it to lethal velocity.