We are usually pretty safe, I don't think there has been anything worse than minor cuts and scrapes in the history of the team, but there are tons of those.
While using our CNC minimill, I forgot to turn on the coolant for some reason. I finally noticed it was making worse noises than usual and ran to turn on the coolant. In the process, I accidentally touched the piece of aluminum I had been milling. Obviously, it was really hot, so I rubbed my hand on my shirt and burned my skin through the shirt. Ouch.
The first time our president got cut by a sharp edge on the robot, he yelled, "Yes! Now my blood, sweat, and tears are
all on this robot!" All of the mechies, myself included, now have blood somewhere on the robot...
Another time, we were all really tired after cadding and fabricating the whole day but we were still working on the drivetrain. One guy, less awake than the rest of us, decided to test if a piece of key stock was sufficiently filed by slashing it down his wrist. Apparently, it stung a lot
Ohh, and last year when we worked on sheet metal we were just covered in cuts. One mechie (same one that slashed his arm with a key) went outside to work on a big piece of sheet metal, and when he was done, his shirt was a different color.