Times Production Ignored Safety Concerns Resulting in Major On-Set Accidents

Making movies and TV shows is incredibly complicated, and sometimes getting things done quickly and cheaply takes precedence over keeping everyone safe. Unfortunately, history shows that cutting corners to get a dramatic shot can have terrible consequences for the people working on set. The following examples highlight times when carelessness, bad planning, or disregarded warnings resulted in serious injuries and even deaths during filming. These incidents are a stark reminder of the dangers present in the entertainment industry when safety isn’t the top concern.

‘Rust’ (2021)

Halyna Hutchins, a cinematographer, was killed in a tragic accident on a movie set when a prop gun fired a live bullet while Alec Baldwin was holding it. The production immediately faced questions about why inexperienced weapons handlers were hired and how live ammunition ended up on set. Several crew members had reportedly quit their jobs just hours before the shooting, citing unsafe conditions and problems with their housing. The incident has led to widespread discussion about whether real guns are truly needed in filmmaking today.

‘Twilight Zone: The Movie’ (1983)

During a nighttime helicopter scene, director John Landis broke child labor laws and safety rules, leading to a tragic accident. Actor Vic Morrow and two child actors were killed when pyrotechnic explosions caused the helicopter to lose control and crash onto them. This horrific event remains one of the worst accidents in Hollywood history, and it ultimately led to new, stricter safety regulations for child actors and the use of helicopters during filming.

‘The Crow’ (1994)

Actor Brandon Lee tragically died on set after being hit by a bullet fragment from a prop gun. The gun had been incorrectly loaded with a real bullet piece left over from an earlier scene, and the crew hadn’t properly inspected it before filming. A blank cartridge then fired the fragment with enough force to wound Lee in the abdomen. This accident underscored the vital need for experienced weapons experts to oversee all gun use on film sets.

‘Resident Evil: The Final Chapter’ (2016)

Stuntwoman Olivia Jackson was severely injured when a camera arm didn’t rise quickly enough during a fast-paced motorcycle scene, causing her to crash into the equipment. This led to a coma and the loss of her left arm. Tragically, later in the same filming, crew member Ricardo Cornelius was killed when a Humvee slipped off a rotating platform and fell on him. The production faced criticism for focusing on elaborate stunts without ensuring proper safety measures were in place for the dangerous equipment used.

‘Deadpool 2’ (2018)

Stunt performer Joi Harris tragically died in a motorcycle accident while filming a stunt. She lost control and crashed through a glass window. According to reports, Harris was a last-minute replacement and didn’t have enough time to practice the particular stunt. She wasn’t wearing a helmet because the actress she was standing in for didn’t wear one in the scene. The accident sparked concerns about whether the need to accurately portray a character’s appearance was being prioritized over safety precautions.

‘Harry Potter and the Deathly Hallows: Part 1’ (2010)

During a rehearsal for a Harry Potter film, stunt double David Holmes suffered a life-changing spinal injury. A stunt involving wires and an explosion unexpectedly sent him flying backward into a wall, breaking his neck. This highlighted the dangers of complex wire work and the significant physical risks faced by stunt performers on large-scale movie productions.

‘Transformers: Dark of the Moon’ (2011)

Gabriela Cedillo, a background artist, sustained severe and lasting brain injury when a snapped cable pierced the windshield of the car she was driving. The cable, used to pull a vehicle during a highway stunt, broke because a weld failed. As a result of the accident, the production company reached a large financial settlement, as it was determined that adequate safety barriers were missing to protect those on set, like Ms. Cedillo.

‘The Dark Knight’ (2008)

Conway Wickliffe, a special effects technician, died in an accident while practicing a car stunt with the Batmobile. He was filming from a moving vehicle when it crashed into a tree at high speed. An investigation found that the rehearsal hadn’t been properly checked for safety risks and the vehicle was going too fast for the situation. This tragic event highlighted that practicing for a film can be just as dangerous as the actual filming process.

‘Kill Bill: Vol. 2’ (2004)

Uma Thurman suffered lasting injuries to her neck and knees when a convertible she was driving crashed during filming. Director Quentin Tarantino convinced her to drive the car herself, even though she felt it wasn’t safe. The sandy road hadn’t been properly prepared, which caused the car to skid and hit a palm tree. Later released video of the crash showed there wasn’t adequate professional stunt supervision for that particular shot.

‘xXx’ (2002)

Stuntman Harry O’Connor tragically died while filming a parasailing stunt where he was meant to fly from a speeding boat and over a bridge. He completed the stunt successfully once, but on a second attempt, he collided with a bridge pillar and died instantly. The film included the footage from his successful first take as a memorial to his work.

‘Top Gun’ (1986)

Art Scholl, a famous aerobatic pilot, vanished while filming a dangerous inverted spin over the Pacific Ocean. He contacted ground control to report a problem with his plane just before it crashed into the water and was lost. What caused the crash – whether a mechanical issue or pilot error – is still a mystery. The film he was working on was dedicated to his memory, acknowledging the significant dangers faced by those who film aerial footage.

‘The Expendables 2’ (2012)

A stuntman, Kun Liu, died and another was seriously injured when an explosion occurred on a boat during a stunt involving pyrotechnics. The explosion happened prematurely or was more powerful than expected while the performers were nearby. The incident, which took place in Bulgaria, has led to legal action questioning safety procedures on international film sets. It underscores the risks of using live explosives when performers are close by.

‘Noah’s Ark’ (1928)

Director Michael Curtiz created a massive flood effect for a scene by unexpectedly releasing 15,000 tons of water. Sadly, three background actors drowned, and many more were injured with broken bones and other wounds. Because safety wasn’t a priority during the early days of filmmaking, extras were often treated as if their well-being didn’t matter. This tragic event ultimately led to the first safety rules being put in place in Hollywood.

‘The Conqueror’ (1956)

The movie was filmed in southern Utah, not far from the Nevada nuclear test site. Although the government claimed the area was safe, radioactive fallout was present. Years later, almost half the people who worked on the film – including John Wayne – were diagnosed with cancer. While a direct link is hard to prove, many believe the cancer cases were caused by exposure to radioactive dust during filming.

‘Roar’ (1981)

The movie was famously dangerous to make because the filmmakers, Tippi Hedren and Noel Marshall, chose to live with and work with over seventy untrained lions and tigers. This meant there were no professional animal handlers to ensure safety, and over 70 people on set were bitten or scratched. One particularly severe incident involved Jan de Bont, who was attacked by a lion and needed more than 100 stitches after his scalp was torn off. Because of the unpredictable and chaotic conditions, the production is widely considered the most dangerous film ever made.

‘American Made’ (2017)

A plane crash in the Colombian Andes killed two pilots and left a third paralyzed. The pilots were flying in bad weather and had reportedly been working long hours to stay on schedule. Legal claims suggested the film companies focused on saving money and time, potentially at the expense of pilot safety and rest. This accident highlighted the difficult conditions faced by film crews working in faraway places.

‘Cover Up’ (1984)

Jon-Erik Hexum, an actor, tragically died in an accident involving a prop gun loaded with blanks. While playfully pointing the gun at his head, he pulled the trigger. The force of the blank cartridge’s wadding caused a skull fracture, and bone fragments entered his brain. This happened on set during a filming break when Hexum was bored and didn’t fully appreciate the danger of even blank firearms at close range. His death serves as a stark reminder that all guns, even those seemingly harmless, must be treated with extreme caution.

‘Vampire in Brooklyn’ (1995)

Stuntwoman Sonja Davis tragically died after a 42-foot fall when an airbag didn’t work as expected. She had previously voiced concerns about the stunt’s safety, but was allegedly urged to continue. The fall caused severe head injuries, and her family is now suing the production team, claiming their negligence led to her death.

‘Magnum, P.I.’ (1980)

Camera operator Robert Van Der Kar died in a helicopter crash while filming a television series. The pilot lost control during a low-altitude shot, and the helicopter went down in the ocean, trapping Van Der Kar inside. The accident highlights the risks involved in filming with helicopters, which often requires flying in challenging conditions.

‘Airwolf’ (1984)

Stuntman Reid Rondell died in a helicopter crash during filming. The crash happened while shooting a high-speed chase scene that needed careful flying. People had previously expressed worry about how difficult the helicopter stunts were for the show. This was a devastating event for a series heavily focused on helicopter action.

‘Ghostland’ (2018)

Taylor Hickson, an actress, was seriously injured on set when she followed directions to hit a glass door with her fists. She was assured the door was made of safety glass, but it shattered on impact, causing her to fall through the broken pieces. The injury needed hundreds of stitches and left her with lasting scars. The film production company was penalized for not properly verifying the safety of the glass.

‘Blade Runner 2049’ (2017)

A construction worker died in Budapest after a film set collapsed while he was taking it down following filming. He was crushed by a piece of the set that wasn’t safely secured. This accident shows that working on film sets isn’t just dangerous for actors during stunts – the construction workers who build the sets also face significant risks.

‘Silence’ (2016)

A construction worker died and two others were hurt when a ceiling caved in at CMPC Studios in Taiwan. The crew was working to strengthen an older brick building to be used as a set for a Martin Scorsese movie. The building unexpectedly became unstable and collapsed on the workers before filming had begun. This accident has brought up questions about the safety of building sets in other countries.

‘L.A.’s Finest’ (2019)

Filming was immediately stopped when a stunt car crashed and severely injured co-showrunner Brandon Becerra, resulting in the amputation of his leg. Though part of a planned sequence, the car missed its target and collided with the area where the crew was monitoring the stunt. The accident was deeply upsetting for everyone involved and caused a pause in production. It highlighted the fact that even designated safe areas on a film set aren’t always completely secure.

‘Titans’ (2019)

Warren Appleby, a special effects coordinator, died in an accident during a rehearsal. A part on a piece of equipment used for a car stunt failed, and a heavy piece hit him. The film production was paused for two days to remember him. This tragedy highlighted the dangers of testing special effects, even when not actively filming.

‘Motherless Brooklyn’ (2019)

Firefighter Michael Davidson tragically died while fighting a fire that started on the set of an Edward Norton movie. The fire began in the basement of a Harlem building being used for filming and quickly spread. Afterwards, lawsuits claimed that flammable materials were stored unsafely, making the fire worse. It was an unusual and devastating incident, as it resulted in the death of a firefighter responding to a film set accident.

‘Skiptrace’ (2016)

Cinematographer Chan Kwok-hung died in a boating accident near Lantau Island, Hong Kong, while filming a scene for a Jackie Chan movie. The small boat he was on capsized due to large waves, and unfortunately, he became trapped underwater. Seven other crew members were able to swim to safety. Authorities determined the accident happened because the boat was operated carelessly in rough seas.

‘Delta Force 2: The Colombian Connection’ (1990)

A helicopter crash in the Philippines during movie filming killed five people: the pilot and four crew members. The aircraft lost power before hitting a cliffside. This is considered one of the most fatal aviation accidents ever to occur on a movie set, highlighting the dangers of filming action scenes in challenging environments.

‘The Sword of Tipu Sultan’ (1989)

A devastating fire on the set of an Indian television series killed 62 people working on the production. The fire began with faulty electrical wiring and quickly spread due to the highly flammable soundproofing materials used on the set. The director, Sanjay Khan, and the lead actor both suffered serious burns, requiring Khan to undergo numerous surgeries. This remains one of the worst tragedies ever to occur on a film or television set.

‘Catch-22’ (1970)

During filming, second unit director John Jordan didn’t use a safety harness while working in an open B-25 bomber. When another plane flew nearby, the resulting turbulence pulled him out of the aircraft. He fell 4,000 feet into the Gulf of Mexico and died. His death was a direct result of not following standard safety procedures for filming aerial shots.

‘The Right Stuff’ (1983)

Stuntman Joseph Leonard Svec died tragically while attempting to recreate Chuck Yeager’s famous high-altitude jump. It appears smoke from a device meant to simulate an ejection seat either impaired his judgment or blocked his view. He didn’t deploy his parachute and died on impact. The incident serves as a stark reminder of the risks involved in combining pyrotechnics with skydiving stunts.

‘Taxi 2’ (2000)

Cameraman Alain Dutartre tragically died on set when a stunt car went beyond its intended landing area and hit members of the production crew. The car, which was meant to land on cardboard boxes, overshot and struck Dutartre and another assistant, causing fatal injuries to Dutartre. The stunt coordinator was later penalized for not adequately protecting the crew.

‘Gone in 60 Seconds 2’ (1989)

H.B. Halicki, the director and star of the film, tragically died in an accident during the preparation for a stunt. A cable supporting a water tower broke, causing the tower to fall and crush him. Because of his death, the movie was never finished. While Halicki was famous for including car crashes in his films, it was a falling structure, not a vehicle, that ultimately caused the accident.

‘The Return of the Musketeers’ (1989)

Roy Kinnear, an actor, broke his pelvis in a fall from a horse while filming a scene. He was hospitalized in Madrid but sadly passed away the next day from a heart attack caused by his injuries. His family later received compensation after demonstrating that the film crew had disregarded his request for a stunt double. Following this tragedy, the director, Richard Lester, stopped making films.

‘The Flight of the Phoenix’ (1965)

Stunt pilot Paul Mantz died in a plane crash while practicing a difficult takeoff for a film. His plane hit a small hill after its landing gear got stuck, causing it to flip repeatedly. Mantz was killed instantly, and another stuntman on board was seriously injured. The accident tragically ended Mantz’s career as one of Hollywood’s top flying professionals.

‘Maze Runner: The Death Cure’ (2018)

As a movie fan, I was really shocked to hear about Dylan O’Brien’s accident on set. Apparently, during a car stunt, the harness that was supposed to keep him safe failed when he was moving between vehicles. It was a terrifying situation – he ended up being dragged along and suffered a concussion, a broken face, and some brain trauma. Production had to completely shut down for months while he recovered. It just goes to show you that even when everything is carefully planned, things can go wrong so quickly with stunts like that.

‘Star Wars: The Force Awakens’ (2015)

On the set of the Millennium Falcon, Harrison Ford was seriously injured when a hydraulic door unexpectedly fell on him. The door pinned him to the floor, breaking his leg and ankle. An investigation found the production company at fault for safety violations, revealing the door had struck with the force of a small car. Fortunately, the emergency stop button was activated, preventing what could have been a deadly accident.

‘F9’ (2021)

Stuntman Joe Watts was seriously injured after a 25-foot fall onto concrete when a safety cable broke during a stunt. He was put into a medically induced coma and faces a lengthy recovery from what are expected to be permanent, life-altering injuries. An investigation found that the cable hadn’t been properly inspected to ensure it could handle the demands of the stunt. Filming was immediately stopped as everyone on set reacted to the shocking accident.

Please share your thoughts on these production tragedies in the comments.

2026-01-29 20:19