If we consider original trilogy return edge, it’s not something of strong focus.
the reason being some of the armour had them, most of the parts actually didn’t.
Where return edge comes into our world is basically to give the real armour a look of thickness, rather than actual 1.5mm thickness of the ABS material it is made of.
On some parts, return edge is either desirable or necessary, on other parts it is either not needed or minimal in width for wearability and to an extent, pure comfort.
A sculpted figurine will generally come down to artistic license, so there can be differences from various source materials plus we have never seen a live action version of this character. Due to this a happy medium can be drawn.
Your points on the weapons are interesting, and it is a shame the B version armour parts aren’t readily available otherwise it would be easy to have both an A and B option in the one CRL and all would be easy.
Fantastic input and research on this great character so far, you are definitely on the right track here with your outstanding observations.