Accidents on sets are rare, but real — and almost always preventable. They occur when protocol failures, schedule pressures, or negligent decisions put safety on the back burner. Below, we revisit emblematic cases, from the recent Rust, to other episodes that prompted safety changes in the industry.
Rust (2021–2024): Rehearsal Shot, a Life Lost, and Trials
On October 21, 2021, during a rehearsal on the set of the western Rust: A Lei do Oeste in New Mexico, actor Alec Baldwin accidentally fired a gun that contained live ammunition. The shot killed cinematographer Halyna Hutchins and injured director Joel Souza.
The investigation pointed to a series of failures. The first assistant director, David Halls, admitted to not checking the weapon properly and reached a plea deal in 2023. Armorer Hannah Gutierrez-Reed was convicted of involuntary manslaughter and received the maximum sentence of 18 months in prison. Baldwin’s trial was dismissed in 2024 after the judge ruled that prosecutors violated rules in evidence handling. In 2025, a separate lawsuit filed by the actor against the prosecutors was also dismissed.
The case remains a tragic landmark of how basic negligence in handling prop weapons can have fatal consequences.
Rust premieres on September 15 on major digital platforms for rent and purchase. Follow Filmelier to find out where to watch.
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Brandon Lee in The Crow (1993): Forgotten Fragment and the Shot That Shouldn’t Have Existed
Perhaps the most well-known case is that of The Crow (1994). During the filming of a scene with revolvers using dummy rounds (prop cartridges without gunpowder), a projectile fragment became lodged in the barrel after a previous take. Later, when a blank (a gunpowder charge without a projectile, known in Brazil as a “bala de festim”) was fired, the pressure caused the fragment to be expelled like a real bullet. Brandon Lee, son of Bruce Lee, was hit in the abdomen and died hours later.
Filming was suspended for a few weeks. The studio decided to complete the film using stunt doubles, rewritten scenes, and visual effects, preserving the footage Brandon had already shot. The Crow was dedicated to the actor’s memory and became a cult classic — both for its dark style and the tragedy that marked its production.
A new version premiered 30 years later, this time starring Bill Skarsgård.
Twilight Zone: The Movie (1982): Helicopter, Pyrotechnics, and Three Deaths
During the filming of one of the segments of Twilight Zone: The Movie (1983), a helicopter lost control after crossing paths with pyrotechnic explosions. The aircraft fell on actor Vic Morrow and two children hired for the scene, Myca Dinh Le and Renee Shin-Yi Chen. All three died on the spot.
Director John Landis and other crew members were prosecuted but were ultimately acquitted. Nevertheless, the accident led to profound changes in the industry. The main one was the revision of rules for the work of minors on sets: formal authorizations, limited hours, supervision by legal guardians, and a total restriction of children in scenes with special effects, weapons, or vehicles became required.
The tragedy also exposed the risks of combining haste, tight budgets, and visual ambition — a warning that still resonates today.
Sarah Jones in Midnight Rider (2014): Tracks Cleared Without Authorization
Camera assistant Sarah Jones, 27, died after being hit by a train during filming on a railroad bridge for Midnight Rider. The production did not have authorization to be on that line; a prop stretcher was placed on the tracks. Director Randall Miller pleaded guilty to involuntary manslaughter in 2015. The company Film Allman was cited for serious safety violations by the US labor agency. The case became a symbol of mobilization for safe conditions on set.
After the accident, studios reinforced internal audits to check location permits. Platforms like Safety for Sarah emerged, pushing for work environments where no one can be exposed to risks without legal authorization. Since then, crews often demand written contracts and reports before stepping onto tracks, bridges, or sensitive public areas.
Joi “SJ” Harris in Deadpool 2 (2017): Motorcycle Stunt
Professional motorcycle racer Joi “SJ” Harris died during the filming of Deadpool 2 (2018), while stunt doubling for the character Domino. It was her first time working as a stunt performer. During a motorcycle sequence, Harris lost control and crashed into a building facade. The report indicated blunt force trauma. She was not wearing a helmet — following the characterization of the character, who also appeared without the accessory.
The accident, once again, brought discussions about safety protocols for stunt performers, especially in scenes with vehicles. Since then, the use of helmets digitally camouflaged in post-production has become common, as well as the requirement for professionals with specific experience in film, even if they already have a career in high-risk sports.
Other Accident Cases
Beyond the most well-known cases, other fatal accidents on sets also changed protocols and left bitter lessons for the industry.
Kun Liu in The Expendables 2 (2011)
During the filming of an action scene for The Expendables 2 on a boat in Bulgaria, an explosion got out of control. Chinese stuntman Kun Liu died on the spot, and another professional was seriously injured. The accident exposed the risks of sequences with multiple practical effects in unstable environments. Since then, sets involving water and pyrotechnics require better evacuation plans.
John Bernecker in The Walking Dead (2017)
In July 2017, stuntman John Bernecker fell from about eight meters (26 feet) on a set in Georgia. He did not hit the safety airbag as planned and died from his injuries. The episode led to an immediate production halt and reignited the discussion about safety margins in controlled falls. Today, similar scenes require redundancies — not just one, but two or more protection systems.
Paul Mantz in The Flight of the Phoenix (1965)
A Hollywood veteran and renowned pilot, Paul Mantz died when the improvised airplane built for the film broke in half during a landing scene in a desert area. The accident happened right on the set of the original version of The Flight of the Phoenix. His death led to stricter regulations for flight filming, requiring the presence of civil aviation supervisors on any aerial scene.
How These Cases Changed On-Set Practices
These accidents revealed technical failures, negligence, and pressures for economy and speed. Rust exposed the risks of trivializing care with prop weapons. The Crow showed how a detail ignored on a single night can be fatal. Twilight Zone left deep scars by involving children in dangerous conditions. Midnight Rider became an emblematic case of filming without authorization. Deadpool 2 amplified the global debate on stunt safety.
Tragedies like these resulted in norms that now prevent new losses — even if, on some sets, they insist on ignoring them.
There is no shortcut that replaces checking, preparation, and the authority of those responsible for safety.
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