Big Ideas Lab: The Evolution and Impact of Dyna3D

Episode: DYNA3D
Host: Mission.org
Knowledge Cutoff: October 2023

Introduction

In the latest episode of Big Ideas Lab, hosted by Mission.org, listeners are taken on an insightful journey into the origins, development, and widespread impact of Dyna3D, a pioneering finite element code developed at the Lawrence Livermore National Laboratory (LLNL). The episode delves into how a single piece of code has transcended its initial military applications to become a cornerstone in various industries, from automotive safety to healthcare.

The Genesis of Dyna3D

The story begins amidst the challenging landscape of the 1970s, a decade characterized by disco and bold fashion but lacking in advanced simulation technologies. John Hallquist, the inventor of Dyna3D, recounts his early days at LLNL:

“When I first joined the lab, it was in the nuclear Test Engineering division where they were looking at vulnerability of protective structures such as missile silos...”
[04:28]

Engineers at LLNL faced the daunting task of designing a low-altitude, high-speed bomb delivery system. Predicting whether the warhead would survive impact without physical testing was crucial but unfeasible with the existing two-dimensional finite element codes.

“They were using two dimensional codes, which really can't model a 3D impact.”
[05:06]

Determined to overcome this limitation, Hallquist set out to develop Dyna3D, a three-dimensional finite element code capable of accurately simulating complex impacts. His dedication led to the initial release of Dyna3D in 1976, a significant breakthrough in modeling capabilities.

Transition to Open Source

Despite the success of the first version, Dyna3D was constrained by the computational limitations of the time, running on a CDC 7600 with limited memory:

“We could only run a few thousand elements, maybe 5 to 10,000 elements.”
[06:44]

The advent of the Cray 1 supercomputer in 1978 allowed Hallquist to recode Dyna3D, enhancing its performance and enabling more complex simulations. However, the original weapons project was canceled, prompting Hallquist to pivot. Recognizing the broader potential of Dyna3D beyond military applications, he proposed releasing the code into the public domain.

“In 1978, I applied to have the code released into the public domain.”
[08:12]

This bold move marked a foundational moment for the open-source movement, allowing engineers and hobbyists worldwide to utilize, modify, and expand Dyna3D. Roger Werney, LLNL’s senior advisor for innovation and partnerships, highlights the collaborative spirit that ensued:

“We would share the software widely with universities... users in the outside world... gave us feedback on this thing on a regular basis.”
[08:57]

Impact Across Industries

The open-source nature of Dyna3D fostered rapid growth and diversification of its applications. Its versatility made it indispensable across various sectors:

Automotive Industry

Dyna3D revolutionized crash simulations, enabling automakers to design safer vehicles without the exorbitant costs of physical crash tests.

“Dyna3D became the workhorse for crash simulation in the automobile industry. It saved the automobile industry billions of dollars per year.”
[10:40]

Aerospace and Defense

In aerospace, Dyna3D was utilized to simulate bird impacts on jet engines, aiding manufacturers like Boeing and regulatory bodies like the FAA in certifying engine modifications without costly physical tests.

“They wanted to use the simulations to justify the changes because the testing cost millions and millions of dollars.”
[13:36]

Manufacturing and Consumer Goods

Even industries seemingly unrelated to defense benefited from Dyna3D. For instance, Coors Brewery employed the code to optimize high-speed production lines for beer cans, ensuring structural integrity while minimizing material usage.

“In the 1990s, even the Coors Brewery turned to the Dyna code for the company's high speed production lines...”
[14:50]

Healthcare

Perhaps the most transformative application of Dyna3D lies in the healthcare sector. Bioengineers utilize the code to model surgical impacts, bodily injuries, and the design of medical equipment, advancing both patient safety and medical device innovation.

“Dyna3D and various other codes have been used to model the impact on human bodies... to model the pacemaker and the electrical current hits the muscle.”
[16:17]

From Government Research to the Private Sector

Recognizing the immense commercial potential of Dyna3D, John Hallquist transitioned from his role at LLNL to establish Livermore Software Technology Corporation (LSTC). Here, he reintroduced and enhanced Dyna3D, rebranding it as LS Dyna to compete in the burgeoning private sector.

“I enhanced the software and reintroduced it as LS Dyna.”
[12:10]

Despite stiff competition from established players like ESI and Mecalog, LS Dyna swiftly dominated the automotive crash simulation market, capturing approximately 90% market share.

“Eventually we took over about 90% of the crash market.”
[12:40]

Continuous Evolution and Future Prospects

LS Dyna's success is attributed to its continuous optimization and adaptability. Roger Werney emphasizes the code’s ability to integrate structural performance with heat transfer and chemical kinetics, broadening its applicability to fields like battery technology.

“The coupling of electromagnetics, heat transfer and structural response via these codes is turning out to be a very valuable new feature.”
[15:59]

Looking ahead, Dyna3D is poised to drive breakthroughs in various domains, including protein folding simulations and the design of safer, more efficient vehicles. Its robust framework ensures that Dyna3D remains at the forefront of engineering and scientific innovation.

Conclusion

From its origins in nuclear engineering to its pivotal role in shaping modern engineering practices, Dyna3D exemplifies the profound impact of open-source collaboration and innovative engineering. As Roger Werney aptly puts it:

“Dyna is to finite element codes what Hershey is to chocolate bars and Kleenex is to tissues.”
[16:38]

Its legacy as an unsung hero continues to safeguard lives across multiple industries, laying the groundwork for the advanced 3D simulations that are integral to today’s technological advancements. As Dyna3D evolves, it promises to expand the boundaries of what is possible, ensuring its place as an essential tool in the engineer’s toolkit for decades to come.

Notable Quotes

• John Hallquist on the inception of Dyna3D:
  “They were using two dimensional codes, which really can't model a 3D impact.”
  [05:06]

• Roger Werney on the collaborative development of Dyna3D:
  “When he found a bug in the code, he would work all night fixing that code so that the next day you could go back and do your calculations.”
  [09:40]

• John Hallquist on transitioning to the private sector:
  “I thought that if things really didn't work out, I would move to Michigan and work for one of the tier one suppliers to the automotive companies.”
  [11:29]

• Roger Werney on LS Dyna’s market dominance:
  “From the standpoint of our impact on the commercial world, it may very well be one of the biggest successes we've had.”
  [11:14]

Dyna3D's journey from a specialized military simulation tool to a versatile, industry-standard application underscores the transformative power of open-source software and dedicated innovation. Whether safeguarding national security, enhancing vehicle safety, optimizing manufacturing processes, or advancing medical technology, Dyna3D remains a testament to the enduring legacy of Lawrence Livermore National Laboratory's commitment to groundbreaking science and technology.