TVLine has published an article detailing nine cases where actors suffered lasting physical damage during TV productions, ranging from costume-related issues to stunt accidents. The piece emphasizes the risks even in seemingly safe shows, with performers like Rachel Brosnahan and Jonathan Goodwin facing fused ribs and paralysis. These stories highlight ongoing safety concerns in television filming.
Overview of Injuries
The TVLine article, published on November 9, 2025, compiles incidents where actors endured permanent harm on set. It notes that while many performers do their own stunts, even simple scenes can lead to disasters, with some recovering without surgery like Stephen Amell on 'Heels,' but others facing lifelong consequences.
Costume and Dialogue Strain
Rachel Brosnahan, starring as Midge Maisel in 'The Marvelous Mrs. Maisel,' developed fused ribs from wearing corsets while delivering rapid dialogue. On 'The Late Late Show with James Corden' in 2020, she explained, 'We talk so fast on the show that to get all the words out you can't really take very many breaths... some of my ribs are sort of fused together a little bit, and I can't take super deep breaths anymore.' Louisa Jacobson of 'The Gilded Age' reported similar rib pain from corsets.
On-Set Accidents
Kristin Chenoweth suffered a skull fracture, broken nose, cracked rib, and nerve damage on 'The Good Wife' in Season 4 when lighting equipment struck her head. In her book, she credited hair extensions for mitigating worse injury: 'My head cracked against the curb, leaving a seven-inch gash that would have been worse... if not for the tightly woven hair extensions.'
Andrew Flintoff's 2022 'Top Gear' crash in a Morgan Super 3 caused broken ribs and facial injuries, leading to BBC cancellation and an $11.3 million settlement. He shared in a Disney+ documentary, 'I thought my face had come off. I was frightened to death.'
Stunt and Fight Mishaps
Kenny Johnson incurred nerve damage and needed hip surgery on 'S.W.A.T.' after a 2018 helicopter stunt, later suing Sony and settling out of court. Jonathan Goodwin became paralyzed from the waist down during a 2021 'America's Got Talent: Extreme' rehearsal explosion, losing a kidney and suing producers in 2023.
Jeffrey Dean Morgan broke both feet on 'The Walking Dead' from poor footwear and jumps, delaying surgery due to COVID-19 fears. He told Business Insider in 2022, 'It started off as kind of nothing, a hairline fracture... The bones in my heel aren't smooth anymore.'
Janice Pennington's 1988 fall on 'The Price Is Right' from a camera bump required surgeries, shortening one shoulder. William Shatner and Leonard Nimoy developed tinnitus on 'Star Trek' from a Season 1 explosion. Ralph Ineson sued Disney over shoulder damage on 'Willow,' settling out of court.
These cases illustrate persistent hazards in TV production despite safety measures.