10 actors who had near-fatal accidents on film sets

Behind all that glamour of Hollywood lies a cold, hard reality: actors often risk death while bringing their stories to life. From risky stunts to on-set accidents, the profession of acting is not always as secure as it appears. While we marvel at their work on screen, we do not usually take into consideration the bodily dangers these actors undertake. Some actors refuse stunt doubles, while others unwittingly walk into scenes that can go horribly wrong. An actor's dedication to their character can occasionally result in near-tragedies, leaving scars that are both physical and psychological.

Here, we list ten such actors who had near-fatal experiences while shooting. They risked their lives and limbs, withstanding smashed bones, serious injuries, and in some instances, close calls with death itself. Even more startling is the fact that a majority of these actors came back to the set with greater dedication to the craft. Their testimonies are chilling reminders of the hidden risks artists take for the sake of our entertainment. While the limelight tends to highlight fame and wealth, it's about time we acknowledge the greater risks these actors face as well. Let's examine ten actors who lived through their worst on-set accidents and lived to tell the story.

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Actors who had near-fatal accidents on movie sets

1. Tom Cruise – Mission: Impossible – Fallout (2018)

Tom Cruise's death-defying stunts are legendary, but one jump during Mission: Impossible - Fallout almost grounded him for life. When jumping across rooftops in London, Cruise overestimated the distance and landed with a thud on his ankle. What's crazy? He completed the shot, you can even spot the limp in the final cut. The shoot stopped for weeks, costing millions. Nevertheless, Cruise showed up early afterward, earning the respect of the crew and giving studio insurers a scare. Despite the injury, Cruise took it as motivation to push his subsequent stunts higher, solidifying his status as Hollywood's most daring action hero.

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2. Jackie Chan – Armour of God (1986)

Jackie Chan has put his life in jeopardy more times than any stunt double, but his on-screen fall during Armour of God nearly killed him. While jumping onto a tree branch, he fell, hit the ground, and fractured his skull. A bit of bone was driven into his brain, and he was rushed to the hospital for emergency surgery. This caused permanent hearing loss in one ear. However, the accident did not deter him; he went back to the set in a few weeks. Nowadays, Chan often jokes about having "hospital VIP status," but this injury remains among the most frightening moments of his career. His X-rays have even been on display at Hong Kong museums!

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3. Harrison Ford – Star Wars: The Force Awakens (2015)

While filming on the set of Millennium Falcon, a hydraulic door came crashing down on Harrison Ford's leg, breaking it in several spots. The extent of the injury stunned the cast and crew, causing the production to be halted for more than a month. What's surprising? The UK Health and Safety Executive subsequently fined Disney's production company $2 million for not keeping cast members safe. Fortunately, Ford, who was in his 70s already, recovered soon enough and came back to shoot the rest of the film like a true legend. Later, he joked that Han Solo might be "out of hyperspace, but not out of action."

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4. Sylvester Stallone – Rocky IV (1985)

Stallone insisted on making the climactic fight between Rocky and Drago feel real, so he had Dolph Lundgren actually punch him. Bad choice. A single chest-busting wallop jounced Stallone's heart against his ribcage, causing it to swell in such a way that its effects resembled a heart attack. He was flown to intensive care and was hospitalized for eight days. Physicians warned that had the punch landed even slightly differently, it would have killed him. Even after surviving such a crisis, Stallone utilized the footage for the final cut. The result? Too real. It is a frightening reminder that even staged brawls can become lethal quickly.

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5. Brandon Lee – The Crow (1993)

Brandon Lee's accident is arguably the most well-known. A prop gun, not cleared of the casing from a dummy bullet, lodged a real projectile into his stomach. He passed away a few hours later on the operating table. Lee had completed shooting for most of his scenes for the film. The Crow became a cult classic with CGI being used to complete Lee's scenes. It stunned Hollywood and prompted more stringent on-set firearm policies. Brandon Lee's untimely death at 28 is one of the darkest fiascos recorded in the history of the film industry.

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6. Isla Fisher – Now You See Me (2013)

In a nightmarish underwater sequence, Isla Fisher's character in the film appears to be trapped inside a tank. The catch? She truly was. The safety release chain malfunctioned, trapping Fisher underwater for almost three minutes, with the crew taking her panicked gestures as part of her performance. She eventually escaped, but the experience traumatized her. However, Fisher completed the scene afterwards in order to maintain continuity. Ever since, she has been vocal about improving safety measures in stunt-heavy productions. Her experience provided the audience with a shudder-inducing, realistic performance.

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7. Dylan O’Brien – Maze Runner: The Death Cure (2018)

While shooting a chase scene, Dylan O'Brien was hit by a car and was dragged, causing him to suffer a concussion, facial fractures, and head trauma. Production was shut down indefinitely, and fans worried that he'd never be the same again. The actor eventually disclosed that he experienced PTSD and deep depression throughout the recovery process. However, what is remarkable is the way O'Brien transformed this experience into motivation. He returned to finish the film and has since chosen to play roles that resonate with him more deeply. This made his return not only a physical comeback but also an emotional victory.

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8. Daniel Day-Lewis – Gangs of New York (2002)

Daniel Day-Lewis is known for being notoriously methodical in his acting, but his immersion almost killed him while shooting for Gangs of New York. Refusing contemporary clothing while shooting in subzero temperatures, he contracted pneumonia. However, the actor refused treatment. The Academy Award-winner wanted to be immersed in character, wearing 19th-century tatters even off-set. Director Martin Scorsese had to intervene, insisting that he get medical treatment before it was too late. The episode served to expose both Day-Lewis's commitment and the risks involved in method acting. He subsequently acknowledged the experience as the one where he might have pushed his limits too far, declaring,

"My body doesn't know it's not 1863."

Lesson learned, but what a performance he delivered.

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9. George Clooney – Syriana (2005)

While filming a torture scene in Syriana, Clooney's chair was pulled back abruptly, resulting in a severe spinal injury. He endured brain fluid leakage and debilitating headaches and had reportedly considered suicide from the pain. Following several surgeries and rehabilitation for months, Clooney resumed work, but the injury left him permanently impaired. Currently, he suffers from migraines every day and has an altered spinal positioning. The accident changed his outlook on life. In subsequent interviews, Clooney's openness about pain and resilience made headlines, and in between, he even joked, "Gravity was easier," which featured him in one of the most physically demanding roles.

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10. Jason Statham – The Expendables 3 (2014)

During the shooting of a truck-driving scene, the brakes of Jason Statham's vehicle failed, and he went over a dock and into the Black Sea. Few are aware that Statham used to be a professional diver, and it saved his life. He exited the sunken truck underwater, getting to the surface by mere seconds. The crew and other actors on set were left amazed, complimenting his calm demeanor. More impressive still, he went back to work the same day. The cast reinforced safety measures thereafter, and the tale became legendary among stuntmen. Statham joked subsequently,

"The Transporter almost transported himself to the afterlife."

The guy is as rugged off-screen as he appears on-screen.

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The world of cinema and filmmaking tends to conceal the dangerous reality of actors' lives behind the scenes, who not only act but also do so at a great cost. Though stunt doubles may be available, some actors prefer to double up on their physically risky scenes, showing commitment. These 10 accidents bring to attention the necessity of having strict on-set safety measures, which ensure that actors are better protected. The bravery of these actors leaves a mark on the viewers, who are indebted to them for their willingness to push their physical boundaries and present to the world unforgettable stories.