Buddy Ebsen, who was originally cast as the Tin Man, suffered a severe allergic reaction to the aluminium powder used in his makeup, which left him in critical condition. He was eventually replaced by Jack Haley, who took on the role despite suffering from a serious eye infection during filming.
The Wicked Witch of the West
Actress Margaret Hamilton also faced challenges on set, including severe burns that she sustained during a special effects mishap. In a scene where she was supposed to disappear behind a puff of smoke, the trap door did not open in time and she and her broom caught on fire. Hamilton was hospitalised for weeks and underwent painful skin grafts to treat her injuries.