In the 1980s, in-line skating was on its way to becoming a recreational phenomenon, lending the opportunity for RFA to help engineer one of the products that helped drive its popularity.
In 1986, Rollerblade’s Brennan Olson approached Rogers, Freels & Associates (RFA Engineering) for engineering support on a new generation of in-line skates. Rollerblade already had a strong concept which it wanted to further refine, improve structural integrity, and develop a lighter, more functional skate.
One of RFA’s most important contributions was the redesign of the wheel fastening system. The new approach eliminated washers and metal-on-metal contact while allowing the front and rear wheels to be positioned slightly higher, creating a profile more similar to a hockey blade. The result was a smoother, quieter ride with easier maintenance.
Other contributions included the transition from a steel frame to an innovative lightweight plastic frame. Engineers evaluated material strength, recommended glass reinforcement, performed stress analysis, determined wall and rib thicknesses, and prepared final drawings. This process also included a formal testing program to validate the new design through impact and static-load testing. The resulting Lightning Rollerblade became the first in-line skate on the market to feature a plastic frame. According to Rollerblade, it exceeded sales expectations and became the most popular in-line skate on the market.
For RFA, the project represents an early example of what continues to define the company’s work today: combining practical engineering, analysis, testing, and innovative design to transform promising ideas into successful real-world products. It also demonstrates the value of creative collaboration, as RFA’s strong partnership with Rollerblade contributed to a significant technological advancement that helped bring in-line skating to the mass market.
Why RFA?
RFA Engineering boasts a history of reliable partnerships and innovative solutions driven by an experienced, creative team focused on strategic success and customer satisfaction. Want to Learn More and Discuss Your Project? We’re here to support you. Contact us today to get started.
