Actors Who Returned after Major Injuries or Surgeries

Setbacks on set or off can halt careers, but many performers have navigated serious injuries or surgeries and still made it back to demanding roles. Below are notable cases where actors recovered, rehabilitated, and returned to finish productions or continue major projects. Each entry highlights what happened, the treatment or recovery, and the work they resumed. It’s a straightforward look at the facts behind some of the most publicized comebacks in film and TV.

Jeremy Renner

In January 2023, Jeremy Renner sustained severe trauma in a snowplow accident, including orthopedic injuries and chest reconstruction. After extensive rehabilitation, he returned to lead season 3 of the series ‘Mayor of Kingstown’. Production restarted with accommodations for his recovery while he continued physical therapy. His on-set return marked his first sustained screen work since the accident.

Emilia Clarke

Emilia Clarke survived two brain aneurysms—one treated with endovascular coiling and another requiring surgery—during the early run of ‘Game of Thrones’. She resumed filming after each procedure under medical supervision. Clarke later founded a charity to support brain injury recovery. She completed the series while maintaining regular follow-up imaging and care.

Tom Cruise

Tom Cruise broke his ankle performing a rooftop jump during ‘Mission: Impossible – Fallout’. Production paused to allow for surgery and healing. He returned to complete remaining stunts, including chase sequences originally adjusted for his limited mobility. The film finished principal photography with revised scheduling to match his recovery milestones.

Harrison Ford

Harrison Ford fractured his leg on the ‘Star Wars: The Force Awakens’ set when a hydraulic door closed on him. He underwent surgery in London and recuperated while the production reorganized the shooting schedule. Ford returned to set after several weeks to continue principal photography. The incident also prompted updated safety protocols for mechanical set pieces.

Daniel Craig

While filming ‘No Time to Die’ in Jamaica, Daniel Craig suffered an ankle ligament injury that required surgical repair. Second-unit work proceeded as his scenes were delayed. After post-operative recovery and physiotherapy, Craig returned to complete the role. Additional action sequences were staged to accommodate his graded return to full movement.

Dylan O’Brien

Dylan O’Brien sustained multiple injuries—including facial fractures—during a vehicle stunt on ‘Maze Runner: The Death Cure’. Production shut down to allow for reconstructive procedures and rehabilitation. Filming later resumed with modified stunt planning and safety reviews. O’Brien completed principal photography and subsequently returned to other projects.

Charlize Theron

Charlize Theron suffered a neck injury—a herniated disc—while performing a stunt on ‘Aeon Flux’. The production paused as she underwent treatment and recovery. She returned to finish the film after physicians cleared her for controlled movement. Subsequent stunt choreography was adjusted to limit axial loading on the cervical spine.

Keanu Reeves

Before filming ‘The Matrix’, Keanu Reeves underwent cervical spine fusion surgery that restricted his neck mobility. Fight choreography in early training shifted to emphasize upper-body techniques and reduced high kicks. Reeves proceeded with filming after medical clearance, completing the role with tailored action design. Wire work and camera setups supported the limitations during recovery.

Henry Cavill

Henry Cavill experienced a hamstring injury during location filming for ‘The Witcher’ season 2. Production reorganized while he followed a rehabilitation program focused on gradual load and range-of-motion restoration. Cavill returned to set with adjusted action blocking. Shooting continued with staged sprint and fight work to minimize re-injury risk.

Sylvester Stallone

Sylvester Stallone sustained a neck injury during a fight scene on ‘The Expendables’ that required surgical intervention and a metal plate. After recovery, he completed post-production duties and continued the action franchise. Later training and stunt plans incorporated additional doubles and safety measures. Stallone went on to film subsequent installments and spin-offs.

Jackie Chan

Jackie Chan fractured his skull performing a tree jump on ‘Armor of God’, requiring emergency brain surgery. Filming halted while he recovered. After a monitored rehabilitation period, Chan returned to complete the movie with revised stunt execution. The incident led to lasting safety adjustments on his productions.

Mark Hamill

Mark Hamill suffered facial injuries in a car accident prior to ‘Star Wars: The Empire Strikes Back’. He returned to the franchise after medical treatment and recovery. Makeup and story elements—including the early Hoth sequence—were used to maintain visual continuity. Hamill completed the film and continued in subsequent entries of the series.

Brendan Fraser

Brendan Fraser sustained a series of stunt-related injuries over multiple productions that led to surgeries on his knee, back, and vocal cords. He underwent repeated rehabilitation while spacing procedures between projects. Fraser continued acting through the recovery periods and later took time off to complete additional medical work. He returned to prominent roles including ‘The Whale’ after regaining fitness for sustained screen work.

George Clooney

While filming ‘Syriana’, George Clooney suffered a head and spine injury that resulted in a cerebrospinal fluid leak. He required hospital care and subsequent procedures to repair the damage and alleviate chronic headaches. After recovery, Clooney resumed work and completed awards-season campaigns tied to the film. He continued acting and directing, returning to set on later projects without long-term production limits.

Uma Thurman

Uma Thurman was injured in a car crash during a driving sequence on ‘Kill Bill’. She received medical treatment for neck and knee issues and took time away to recover. Production support and therapy helped her return to normal activity levels. Thurman later headlined additional action and drama projects without the same stunt demands.

Blake Lively

Blake Lively injured her hand during an action scene on ‘The Rhythm Section’, which required surgery. Filming shut down to accommodate her recovery and hand rehabilitation. Once cleared, she returned to complete principal photography with revised stunt planning. The production adjusted choreography to protect the surgical repair during close-quarters scenes.

Halle Berry

Halle Berry broke ribs training for ‘John Wick: Chapter 3 – Parabellum’. She paused work to heal under physician supervision and continued conditioning with modified drills. Berry returned to set and finished her action sequences after clearance. She later applied similar training protocols when preparing for the MMA drama ‘Bruised’.

Michelle Yeoh

Michelle Yeoh suffered serious spinal and soft-tissue injuries performing a stunt on ‘The Stunt Woman’. She underwent hospital treatment and a structured recovery program before resuming work. Yeoh returned to action roles with careful stunt design and supervision. Subsequent productions incorporated additional safety measures to manage risk during complex wire work.

Orlando Bloom

Orlando Bloom broke his back in an off-set accident early in his career. After surgery and months of rehabilitation, he returned to sustained physical roles. He performed demanding sequences in the ‘The Lord of the Rings’ trilogy with activity constraints lifted gradually. Bloom continued with action-heavy projects such as ‘Pirates of the Caribbean’ while maintaining conditioning routines.

Robert Downey Jr.

Robert Downey Jr. injured his ankle during a stunt for ‘Iron Man 3’, which paused shooting. He received treatment and followed a rehabilitation plan focused on stability and load tolerance. Filming resumed with adjusted schedules and selective use of a double for high-impact beats. Downey returned to complete the film and continued appearing in action-intensive projects.

Pierce Brosnan

Pierce Brosnan suffered a knee injury while filming ‘Tomorrow Never Dies’ that required surgical repair. Production reshuffled the schedule while he recovered mobility. Upon returning, he completed dialogue and controlled-action scenes before advancing to more dynamic work. Brosnan continued the franchise with modified stunt planning to reduce strain.

Viggo Mortensen

Viggo Mortensen broke toes during a combat scene after kicking a prop helmet on ‘The Lord of the Rings: The Two Towers’. On-set medical care and rest periods allowed him to continue filming with managed pain. Staging and camera placement were adjusted to minimize weight-bearing stress. Mortensen finished the film and participated in subsequent location shoots.

John Cho

John Cho suffered a knee injury on the set of ‘Cowboy Bebop’ that required surgery and an extended rehabilitation period. Production was delayed while he completed physiotherapy and regained strength. Cho eventually returned to finish the season’s action work under movement restrictions. The series wrapped principal photography after reworked scheduling.

Ruby Rose

Ruby Rose underwent spinal surgery following two herniated discs incurred during action work on ‘Batwoman’. Recovery included restrictions on lifting and high-impact movement. She returned to screen projects with more conservative stunt participation. Later roles were planned with additional doubles and safety oversight.

Shia LaBeouf

Shia LaBeouf injured his hand in a car accident during the period surrounding ‘Transformers: Revenge of the Fallen’, requiring surgery. The production incorporated his hand brace into costuming while he healed. Shooting schedules and scene blocking accounted for limited grip strength. LaBeouf completed the film and resumed additional projects afterward.

Hugh Jackman

Hugh Jackman underwent multiple procedures for basal cell carcinoma, including excisions on his nose. He returned to filming after each surgery with protective dressings used between treatments. Makeup and camera angles concealed ongoing recovery during shoots like ‘Logan’. Jackman has continued to monitor for recurrences while maintaining a full workload.

Val Kilmer

Val Kilmer received treatment for throat cancer that led to a tracheostomy and long-term changes to his voice. After rehabilitation and voice-assist technologies, he returned to screen appearances. He filmed scenes for ‘Top Gun: Maverick’ with accommodations for his vocal limitations. Kilmer has continued to appear at events and in documentaries detailing his recovery journey.

If we missed someone whose comeback deserves attention, share your picks in the comments so we can keep the conversation going.