Manufacturing Processes

MANUFACTURING PROCESSES

Tolerance to the millionth

SUPERB’s high speed, tight tolerance production operations require exacting toll making skills. Toolmakers work to precise tolerances and use high quality and, in some cases, exotic materials to maintain the standards required by its customers.

Skilled grinders specializing in carbide form, surface, and jig grinding can hold tolerance to 20 millionth of an inch using grinding machines in a climate-controlled environment. SUPERB’s tooling longevity is ensured by using tungsten and titanium carbide material in addition to alloyed tool steels.

SUPERB Industries has the following Bihler manufacturing technology:
  • GRM80 Bihler Manufacturing Cells
  • GL3000 Bihler Manufacturing Cells
  • Bimeric 1500 Bihler Servo Cells
  • Bimeric 3000 Bihler Servo Cells

Bihler manufacturing systems perform the following processes from the very start to the finish:

  • Stamping
  • Coining
  • Tapping
  • Laser and resistance welding
  • Forming
  • Drilling
  • Punching
  • Component assembly

Where the complexity and flexibility of a Bihler process are not required, our Bruderer servo presses provide an efficient alternative to conventional stamping technology. Our 30 and 75-ton Bruderer high speed presses, equipped with custom-designed class high-speed carbide dies, operate at two to three times the production rate of conventional stamping machines.

Terminals & Connectors
SUPERB manufactures a wide range of terminals and connectors to customer specifications for the automotive, appliance, security, electronics, constructions, telecom, medical, and commercial markets. Our high-speed Bruderer stamping presses combined with SUPERB’s best-in-class carbide tooling provide a cost-effective process that ensures consistent quality. We can process brass, copper, and precious metal alloys and package the final product in bulk, reel to reel or stacked for automated assembly. We can manufacture terminals from pre-plated material or have them post plated after stamping depending on customer specifications. All types of plating are available including precious metals. We offer burr-free parts using two different methods. The preferred method is conditioning the terminals in the die so that all burrs are removed when they come off the press. We can also remove burrs using vibratory finishing equipment as a secondary process after stamping.

Precision Stampings
SUPERB has developed a reputation for close tolerance stamping. When tolerances are =/- 0.001” and the volume is more than 100,000 pieces, SUPERB is the right choice.

Precision Drawn Components
SUPERB has taken the techniques of progressive drawn components to a new level. With our precision tooling and high-speed presses, we routinely produce drawn components at nearly twice the typical speeds. However, we do not sacrifice quality for the sake of speed. Our efficient process maintaining process capability of Cpk2.0+.

Lead Frames and Reel-to-Reel Stampings
SUPERB uses high-speed Bruderer press to produce lead frames and reel-to-reel stampings. Our precision carbide dies and dedication to quality ensures that we deliver consistent quality parts to customer specifications. Stampings packaged in a reel-to-reel format provide our customers with a convenient and economical way to automate assembly.

SUPERB Solution
Leveraging the cosmic principles of time and space to increase production and reduce cost.

Problem: A customer asked SUPERB to transfer and old process used to manufacture drawn cups. The old process output was 100 pieces per minute and material consumption wasted a lot of space.

SUPERB Solution: First SUPERB optimized the old process to increase output to 200 parts per minute. Then designed a new process to leverage time and space, focusing on increasing the speed and reducing the material used.

Result: Output increased to 600 drawn cups per minute with a 30% savings on material.

Injection Molding

SUPERB’s innovative molding processes injects value into every product. With the ability to run engineered resins, insert and over mold different materials, SUPERB’s molding department is the one stop source to meet your injection molding requirements. State-of-the-art injection molding presses and process technology offers the highest precision and flexibility for the most diverse applications, including: reel to reel terminal over molding, robot assisted processes, insert molding, nut insertion and molding, over molding bumper bolts, and shuttle press molding.

SUPERB Industries has the following injection molding equipment:
  • 230 Ton Battenfeld
  • 150 Ton Battenfeld
  • 110 Ton Battenfeld
  • 40 Ton Battenfeld
  • 200 Ton Van Dorn
  • 150 Ton Newbury
  • 75 Ton Newbury
The department’s peripheral equipment includes isolated Comet Material Dryer System, surge bins and computerized vacuum feed system, AEC Chiller System, Mokon Thermolators, and material grinders.

Assembly Systems

SUPERB offers value added manual and automated assembly of components to provide customers with just in-time finished products ready for the assembly line. Whether it is assembling manufactured or purchased components, the SUPERB assembly systems is an unbeatable advantage that is personified by teamwork.