A broken knuckle and getting stabbed in the face with a semi-sharp sword that resulted in a hospital visit were my worst!

I’m sorry this happened to you. It does sound like you and your group went way too far for the equipment you were using.

Usually theres a tradeoff between historical accuracy, safety equipment and sparring intensity.

If you have no adequate hand protection for historical reasins, you either need lower intensity or explicitly forbid hand hits.

If you want to fight at full intensity of you need to fall back on less accurate protection and maybe even still adjust rulesets.

If you want accurate swords with no rolled / flared point, you must change how thrusting works.

I got a fencing mask imprinted on my forehead once because we also went too intense with polearms for the gear we had.