I don't believe that there are any serious 1911 makers using cast slides. Most are made from forgings or bar stock including all of the manufacturers being discussed here.
Thumb safety breakage isn't very common but when it happens, it's usually at the joint where the pin meets the body of the safety (on standard, non-ambi versions). Either they break like the one shown in the above photo or the pin shears off at the joint.
My contacts at Nighthawk and Wilson work very hard to take care of their customers and build the best guns possible. They are also constantly trying to develop better parts for their pistols to help reduce breakage.
I'm glad to hear that Nighthawk took care of you.
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