I believe I had at one time have a dwarf recover from having a hand cut off, took him ages, but he managed to do most of his tasks without problems.
Was that in a previous version, like 38c? I can remember anecdotes to that effect as well, but not since 39a and onward. I'm fairly certain the permanent bedrest is a consequence of the recuperation system Toady implemented in the newest versions of DF.
Actually, I just checked the save file, somehow he managed to survive having all his fingers on his right hand cut off(Including thumb), but the hand itself is still attached to him. His left foot is also missing 3 toes.
Besides that, sparring incidents are common with me, a good weapon is higher priority then good armour. I can always get another soapmaker, but I'm just not into micromanaging sparring weapons/real weapons, making sure dwarves get the right armour, etc. I just set half of them to plate armour, the other half to chain, and they can go loot if the goblins kill a dwarf caravan(I would probably give them a bin of stone mugs for that armour anyway).
Eventually I made enough weapons for them all and I start slowly working on the armour, only top quality from the best steel, made by a legendary armoursmith in small locked magma forges. Any armour or weapon less then masterwork quality gets tossed into a pit next to the magma smelters, and I use locked doors to make sure it all gets recycled. Only the best is good enough for my dwarves, if I can't give them the best, they can be naked wrestlers for all I care.
Sometimes I think I carved the barracks out of bauxite or kaolinite.