Re: Beefing up Villians
Another thought is for the villains to recruit, or even temporarily hire, someone that would work very well against the heroes by taking advantage of a hole in the heroes' MO.
For example, in my game none of the PCs have Area Effect damage attacks, and only one can affect desolidified targets. So one master villain recruited Pestilence, a shrinker who can summon swarms of stinging/biting insects to harass the heroes.
Are the heroes mostly ground-bound? Pick a fight in an open-air area, and hire some thugs to attack from rooftops with No Range Mod sniper rifles.
Are the heroes weak in enhanced senses? Hire someone with Invisibility to ambush them in combat.
Is one hero the damage sponge? Ignore him and concentrate on taking out his softer teammates first.
Villains can have key info on the heroes (vulnerabilities, susceptabilities), even if was never displayed in combat against that particular villain. I introduced an organization (CrimeNet) into my game that collects and disseminates info on individual heroes and hero groups, for a small fee. They start hero fan clubs and internet chat rooms and discussion boards dedicated to the heroes, giving them a lot of unwitting help in collecting this information. This made a fun plotline for the heroes to follow up on, after they discovered different groups of enemies all possessing similar printouts on their powers and tactics.