Was Space Shuttle safe enough for human crews?
Space Shuttle was a compromised design from the beginning. They originally wanted the Space Shuttle booster to also have wings and return to launch site (with a crew!). But they couldn't afford to develop two new vehicles, so they compromised by making the external tank as cheap as possible and adding solid rockets (which led to the Challenger disaster).
But their biggest mistake was having the engines on the orbiter (so they could be recovered) but not the fuel tank. That meant the orbiter had to hang on the side of the external tank, which made it vulnerable to foam strikes (leading to the Columbia disaster).
Landing with wings is aesthetically pleasing (compared to tower catches) but consider the waste: You have to boost the weight of the wings, landing gear, etc. all the way to orbit and then bring it all the way back. It's much more efficient to just bring fuel and use that for landing. And if your guidance is accurate enough, a pinpoint landing means you can land on the launch tower and not worry about landing legs.
I tend to think that for human rated flights it may be possible to give it a parachute just in case powered descent is not possible for any reason as a precaution for a belly flop water landing with parachute assist. The flaps are already there too so maybe just increase their size is possible for a glidable descent? We're entering a size class for the vehicle that makes some outside the box stuff possible without sacrificing too much in terms of payload capacity.
For the shuttle there was also a lot of interference from the Airforce, which forced them to have a massive payload bay, so AF could launch and service their big Keyhole satellites (and possibly snatch Soviet ones in one orbit without warning).
Then there was pressure to make use of solid propellants to amortize their use with military uses, not to mention pushing for Shuttle carrying all payloads for the US.
This together created the dangerous and expensive design tHat was STS.