In Teen Titans, Robin (being the Badass Normal) is the only character to ever occasionally receive minor injuries, but even those were for the sake of the plot (such as the episode "Fractured") and were invariably gone by the next episode (Raven has Healing Hands, so maybe that part is justified). Other than that, despite having no superpowers whatsoever, he is just as Made of Iron as the rest of his superpowered teammates, sometimes rivaling that of the literally Made of Iron Cyborg.
Brock Sampson has, in various episodes, survived being beaten, stabbed, shot, exposed to the vacuum of space, hit with a bus and buried alive after receiving a supposedly lethal dose of knockout darts. When the Phantom Limb has to perform emergency surgery on Brock to save his life in the episode "Hate Floats" he runs down a litany of all the things he removed.
"I have removed the bullet. And three others, a blowgun dart, two shark's teeth, a tip of a bayonet, a twisted paperclip, and a meager handful of buckshot. You may want to learn how to duck."
To a lesser extent, Dr. Venture is also indestructible, having survived the loss of an arm (later reattached with no ill effects) and having an eye knocked out of its socket (he's forced to wear an eye patch for an episode, but next time we see him, all is well) and kidney removal. Both kidneys, by the way.
Dr. Venture also got crushed by a giant disco ball.
A significant supporting character was Killed Off for Real with what by the show's standards was a relatively minor attack, simply because he was caught by surprise and wasn't able to brace himself for the hit.
The only two people who actually had bones broken were the canyon guide in "The Gread Divide" after being attacked by some canyon crawlyers and Sokka in the Grand Finale by awkwardly falling about ten metres onto a metal platform.
Played for laughs in "The Homer they Fall", where it is revealed that Homer was born with an unusually thick skull and has an extra layer of protective fluid around his brain, so he can take severe, repeated blows to the head without suffering any real damage. Unfortunately, this fails as he faces heavyweight champion Drederick Tatum.
Even outside of the protection afforded him by "Homer Simpson Syndrome," Homer is able to shrug off injuries that would kill lesser men. In Homer Scissorhands, he laments this trait after intentionally drinking a jar of disinfectant:
Homer: (Groans) Why dosen't anything kill me?
And subverted in "Homerpalooza" when the doctor informs him that his cannonball-to-the-gut sideshow act is killing him.
Double subverted in the episode "Bart the Daredevil," when he falls down the Springfield Gorge twice with an ambulance crash in-between, but sustaining severe injuries.
In The Movie of Kim Possible, Shego is kicked from the roof of a building that is several stories high, into an electrical signal tower, which not only electrocutes her but also collapses right on top of her. And she comes out of the incident with slightly torn clothes and frazzled hair...
Just about all the main characters get blasted, smacked, slammed, falls, and runs through other notable dangerous hazards with nothing more then scrapes. Valerie's future self fell hundreds of feet from the sky and lives!
Danny himself, though partially justified through his ghost abilities. Still, given the number of times he gets shocked, blasted, slammed into walls or the ground and overall smacked around by every ghost EVER, he definitely falls into this trope.
Duckman has Big Jack McBastard, who is trampled by a horse, eaten by vultures down to a skeleton, and then buried. At the end of the episode, he shows up to congratulate them on completing their job. When asked how he survived, he takes a drag on his cigar, and says "Long story."
Major Bludd in G.I. Joe: Renegades is a fairly impressive example, taking about as much punishment in one episode as one could theoretically suffer in a kids show, and shrugging every bit of it off like nothing happened. He get punched, kicked, shuriken'd, knocked off a speeding truck through a billboard, smashed into crates, hit with a forklift, buried under debris from a collapsing wall, and finally blown up with a shopping mall/ammo dump. Only after the last one costs him an eye does he start to even hold a grudge against the Joes.
"Did you honestly believe that a mere 39 gazillion tons of red hot metal and duct tape would crush me?"
The Ponies in My Little Pony: Friendship Is Magic receive a lot of their respect among male fans by the constant demonstration that they're pretty much invulnerable. Pianos dropping on them, taking a full buffalo charge, getting hit by dragon breath, hitting a mountain at jet speed, nothing appears to even stun them for more than a few seconds. The first real injury in the series is when one of Rainbow Dash's failed stunts gives her a concussion and a broken wing (A compound fracture, no less) which requires a couple of days hospital stay and staying off the limb for a week.
Based on "Sonic Rainboom", ponies in this show can sustain over 1600 G-forces. This is demonstrated by Rainbow Dash turning on a dime at what was either Mach 1 or Mach 5.
And later we see a flashback where she does it as a young filly. She is a pegasus, and is implied that the earth ponies are the ones more physically able than the other races. If they have health/safety regulations, they are for other animals as the cows and donkeys they live with, because ponies surely doesn't need them.
Special mention goes to Spike, since his dragon scales give him a formidable natural body armor: He's completely fire-proof, at the point he can bathe on magma and sustain neiter pain or damage from stabs, hits or falls. He casually explains this last part while he's being used as a living pincushion by Rarity. Later in the comics he's thrown several miles and straight through a cliff, only to be revealed later to be on the other side unconscious but not otherwise hurt.
Sterling Archer is virtually impervious to pain, most recently walking away from a space shuttle crash unscathed.
Averted with Brett, whose condition steadily worsens every time he gets shot (or savagely beaten). Mallory, who embodies the office's utter indifference to Brett's health, has taken to calling him "Mr. Blood Bank."
Subverted in the 5th season in which during a brief moment Archer reflects on all the injuries he recieved and how each should have left a mark on his body that will get worse with age. He hopes he has dementia before the after effects start showing up.
Fry routinely has entire limbs—and once even his head—severed, but manages to function just fine; rarely even showing any outward sign of pain.
Bender is made of iron (well, 30% iron) in both the literal and figurative sense. He even seems tough by robot standards, having endured being crushed, melted, shredded, eaten, jettisoned into deep space, exploded, and having his components incorrectly reassembled, somehow, into a working flying saucer in the 1950s (long story).
Bender: What does it take to kill me?
Doofenshmirtz on Phineas and Ferb. Every day, Perry ends up foiling his plans in some way, leading to the destruction of one of his many -Inators in a massive explosion or something that will bring some harmful treatment to Doofenshmirtz. In spite of this, he rarely ever seems hurt or displays any kind of bodily damage. So far he's survived fiery explosions, being hit by a giant ball of aluminum, the eruption of a volcano, the sinking of his lair while perched over a crocodile's mouth, crashing headlong into his own building several times, and multiple other situations.
Most of the celebrities on Celebrity Deathmatch keep fighting after things that should incapacitate them. Special mention to Michael Jackson who got kicked into a vat of hydrochloric acid and survived unharmed, and Dave Thomas who gets decapitated and still manages to run around like a mad hen until he falls into a frying pan.
In Britney Spears vs. Christina Aguilera, both combatants rip each other to pieces until all that's left is an arm. A moving arm. Whose arm it is is never revealed.
In Sylvester Stallone vs. Arnold Schwarzenegger, Stallone gets blown into a pile of goo and still manages to heal completely, and even manages to win the match.
Beavis and Butthead have been ran over by multiple vehicles, pulverized on multiple occasions, stricken with several lethal diseases & then some. Their durability has served them well.
Van Drieson is a similar case: He got mauled by a bear, fell down a cliff(twice) & was once ran over by Beavis in a car tire...& he's still alive.
Apparently, Coach Buzzcut can survive being ran into by a steamroller. He can also survive being in the center of a car crash.
Courage the Cowardly Dog can withstand far more punishment then the average dog. He's been brutalized, vaporized, mauled, forced to play an unfair game of dodgeball with many of his old enemies, & crushed. He also gets thrown around on a regular basis. How he managed to survive all of that is unknown.
Jack Nife from Superjail! has been going through hell in his recaptures by the Jailbot since the begining of the series... & not once has he lost his solid form.