Thought being an actor was all glitz and glamour. What about emergency rooms and band-aids?

Filming Lord of the Rings (2001-2003) resulted in a long list of bumps and bruises for actors and extras. In the wide shots of Legolas, Aragorn and Gimli running after the Orcs, all three performers are running injured. Orlando Bloom had a couple of broken ribs (from a fall off a horse); Viggo Mortensen had a broken toe (from kicking the helmet in the Orcs funeral pyre scene); and Brett Beattie (Gimli's stunt double) had a knee injury. Peter Jackson said that all three were very dedicated and continued to film the scene, often yelling "ouch" or "ow" after "cut" was called.

Judy Garland was 16 when she played the role of Dorothy in the Wizard of Oz (1940). During filming she was made to wear a very painful corset so she would appear younger and more flat-chested. To top it off it is believed, Toto, her canine co-star was paid more than she was.

Ironically, Brad Pitt, while playing the role of Achilles in Troy (2004) tore his own tendon, which forced him to delay production of his next feature Ocean’s Twelve (2004).

However the ultimate mishap took place on the set of The Crow (1994) when an incorrectly loaded firearm resulted in the death of the films star Brendon Lee, son of the late Bruce Lee.

Source IMDB