In the world of Hollywood, actors often take on roles that push their physical and mental limits. While some scenes are enhanced through special effects, many stars still choose to perform their own stunts or take on challenging roles that put them at risk. Unfortunately, not all productions go smoothly, and some on-set accidents have left lasting impacts on actors’ lives. Here are eight stars whose careers—and lives—were forever changed by incidents while filming.
1. Buddy Ebsen: A Life-Threatening Reaction
Buddy Ebsen was originally cast as the Tin Man in The Wizard of Oz. However, his role was cut short after a severe allergic reaction to the aluminum powder in his makeup. Just days into filming, Ebsen collapsed, struggling to breathe, and was rushed to the hospital. Doctors warned that continuing the role could be fatal, forcing Ebsen to give up the iconic part. His replacement, Jack Haley, wore a safer, cream-based makeup. Although Ebsen’s scenes were replaced, his singing voice can still be heard in a few musical numbers.
Video:
Buddy Ebsen’s Near-D*ath Experience
2. Margaret Qualley: Skin Damage from Heavy Makeup
Margaret Qualley’s commitment to her role in The Substance left her with unexpected consequences. Wearing heavy prosthetics and layers of makeup for a year caused severe acne that persisted long after filming wrapped. Qualley shared that the glue and synthetic skin clogged her pores, making breakouts relentless. Even during her next project, Kinds of Kindness, the effects were still visible. The crew had to adjust camera angles to minimize her skin issues, but with a dedicated skincare routine, Qualley eventually recovered.
3. Joseph Gordon-Levitt: A High-Speed Crash
While filming Premium Rush, Joseph Gordon-Levitt took on the role of a daring bike messenger. During a chase scene through New York City, he lost control and crashed through a taxi’s rear window, resulting in a gruesome arm injury requiring 31 stitches. Remarkably, Gordon-Levitt was back on set the next day, embodying the fearless spirit of his character.
4. Harrison Ford: The Millennium Falcon Incident
On the set of Star Wars: The Force Awakens, Harrison Ford was seriously hurt when the hydraulic door of the Millennium Falcon unexpectedly came down, breaking his leg. Production was halted, and a safety investigation followed. Disney was fined $2 million for failing to adhere to proper safety protocols. Despite the injury, Ford returned to complete the film after his recovery.
Video:
Harrison Ford Explains His Horrific Accident On The Set of The Force Awakens in June 2014
5. Tom Cruise: A Leap That Broke an Ankle
Tom Cruise’s dedication to authenticity in Mission: Impossible – Fallout led to a painful mishap. While performing a rooftop jump, he miscalculated the landing, breaking his ankle. Instead of stopping, Cruise powered through the take, and the footage made it into the final cut. Production paused to let him heal, but the scene remains a testament to his relentless commitment.
6. Margot Robbie: Ice Skating Gone Wrong
To accurately portray Tonya Harding in I, Tonya, Margot Robbie trained rigorously in figure skating. The physical demands left her with tingling arms, persistent pain, and eventually a herniated disc. Despite the injury, Robbie remained committed to the role, balancing recovery with performance.
7. Natalie Portman: Pushing Through the Pain
While filming Black Swan, Natalie Portman dislocated a rib during a dance lift. With no medic on set, she continued performing despite the pain. Later, as the therapist worked on her injury, director Darren Aronofsky kept the cameras rolling, capturing Portman’s raw determination and the reality of her suffering.
8. Colin Firth: The Role That Affected His Body
Colin Firth’s portrayal of King George VI in The King’s Speech was so immersive that it left him physically affected. Training to mimic a stammer compressed a nerve, causing his left arm to go numb for days. Even when filming ended, the role’s physical strain lingered.
Actors often go to great lengths to bring their characters to life, but sometimes those efforts come at a cost. These on-set accidents not only changed the lives of these stars but also highlighted the risks that come with artistic dedication.
