His first film was the 1985 hit comedy film Weird Science as Max. He appeared later that year in horror film A Nightmare on Elm Street 2: Freddy's Revenge as Ron Grady. While filming the movie, Rob and the star of the movie, Mark Patton became close friends. He also played Richard Lawson in the 1991 TV film Stephen King's Sometimes They Come Back. Other notable film credits include leader of the Daggers Tommy Hook in Thrashin', AJ in Vamp, Buzz Ravenel the townie boy whose come-ons snare Carson in Shag, and Fuad Ramses in the remake of Blood Feast.
Rusler has appeared in television series, such as the short lived 1990 series The Outsiders as Tim Shepard, and in the 1993 series Angel Falls, but his best known TV role was in the 1990s hit science fiction series Babylon 5 as Warren Keffer in season 2 (1994–1995). He has acted in the 1995 sci-fi video game flight simulator, Wing Commander IV which starred Mark Hamill and Malcolm McDowell. He also recently appeared in an episode of the TV series The Unit.
Rusler has made guest appearances on television shows ranging from The Facts of Life, Snoops, Cold Case, Medium, The Unit, The Closer, 24, Navy NCIS: Naval Criminal Investigative Service, and Enterprise in the season 3 episode "Anomaly" as Orgoth. He has appeared in a Heineken commercial directed by Oliver Stone.