An actor’s safety on set should always be the top priority — but sometimes, even the most carefully planned productions can’t prevent accidents. From daring stunts to method acting, these Hollywood stars have risked life and limb to bring unforgettable performances to the screen. Here’s a look at actors who suffered serious injuries while filming, in chronological order.
Tom Hanks in ‘Cast Away’ (2000)
Tom Hanks went full method while filming Cast Away, living in isolation on a deserted island for months to fully embody Chuck Noland. His dedication came at a cost: he sustained a staph infection from a wound on his leg.
Viggo Mortensen in ‘The Lord of the Rings: The Two Towers’ (2002)
Viggo Mortensen’s commitment to authenticity as Aragorn led to a painful accident on the battlefields of Middle-earth. While filming a scene in which Aragorn mourns Merry and Pippin, Mortensen kicked a heavy Orc helmet across the set — and broke two of his toes in the process. The scream of agony heard on-screen is real, and director Peter Jackson kept the take because it captured raw emotion perfectly.
Leonardo DiCaprio in ‘Django Unchained’ (2012)
Leonardo DiCaprio literally bled for his art in Quentin Tarantino’s Django Unchained. While filming the tense dinner scene at Calvin Candy’s house, DiCaprio smashed his hand onto a real glass goblet, which shattered and cut his palm. Remarkably, he stayed in character, even smearing his own blood on Kerry Washington’s face. Tarantino loved the intensity, and the take made it into the final cut.
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Isla Fisher in ‘Now You See Me’ (2013)
Isla Fisher had a terrifying moment during a Houdini-inspired stunt in Now You See Me. Trapped in a water-filled cube with chains that got tangled, she couldn’t hit the panic button or signal the diver nearby. The crew thought she was acting, filming the scene as she desperately signaled for help. “They thought I was being Meryl Streep in the tank,” Fisher recalled. “Actually, I was drowning.”
Margot Robbie in ‘I, Tonya’ (2017)
Margot Robbie’s dedication to portraying figure skater Tonya Harding was extreme. She trained five hours a day, five times a week, and the physical toll included countless bruises, blisters, and a herniated disc in her neck. “My arms started going numb for a month, but it was the disc getting irritated. And then I properly herniated it, and I was very aware when that happened. It’s really painful,” she revealed. Despite the injury, Robbie delivered an Oscar-nominated performance.
Tom Cruise in ‘Mission: Impossible – Fallout’ (2018)
Tom Cruise is famous for performing his own stunts, and during a rooftop chase in London, the actor nearly paid a high price. Jumping from one building to another, Cruise misjudged the distance, smashing his foot and ankle into the concrete. The pain was real, but he pulled himself onto the roof and finished the scene, limping toward the camera. The injury didn’t stop production, showcasing Cruise’s legendary dedication.
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Dylan O’Brien in ‘Maze Runner: The Death Cure’ (2018)
Dylan O’Brien endured one of the most terrifying on-set accidents in recent memory. While filming a stunt, he fell off a moving vehicle and was subsequently run over by another car. He suffered a concussion, multiple lacerations to his face, and significant trauma that affected his ability to perform in later action roles.
Zac Efron in ‘Killing Zac Efron’ (2019)
High School Musical alum Zac Efron took “survival TV” very seriously while filming *Killing Zac Efron* in Papua New Guinea. He contracted what many believe was typhoid fever and had to be airlifted to Australia for urgent treatment. The experience highlighted the risks actors take, even when they’re off a scripted set.
Barry Keoghan in ‘Banshees of Inisherin’ (2022)
Barry Keoghan nearly faced amputation before filming Banshees of Inisherin after contracting necrotizing fasciitis, a flesh-eating bacterial infection with a 20% fatality rate. In a 2023 GQ interview, director Martin McDonagh said, “I’m not sure if he was on a lot of meds, but he seemed to shrug it off.” The resulting scar tissue wound its way up Keoghan’s arm like a “snake tattoo.”
Tom Holland in ‘Spider-Man: Brand New Day’ (2025)
Most recently, Tom Holland sustained a mild concussion during a stunt on Friday, September 19, 2025. Production paused for a week as a precaution while he received treatment at a hospital. Holland is expected to return safely to set without affecting the film’s July 31, 2026 release date. Phew!
