I am currently designing a high speed 3 axis pick and place transfer system, and I need some help.

Due to the fact that I am using servo-motors to move all 3 axis of movement, inertia is a big issue, so every component must be light weight. So I started the concept of my design using aluminum plate, bolted together, to create thex, y, and z carriages. As I got into the design of the machine, I started to wonder if I could save even more wieght and still have the strength if I cast the main carriages / components.

So now I'm doing my research, and since I'm not too familiar with casting, I thought I would ask here.

1. Can anyone point me towards some good literature, books, or internet resources so I can learn more on this subject?

2. Since this is a prototype machine, and basically every design after this one will be somewhat different, I would assume that one off sand casting will be the only solution. Now I realise that casting will be more expensive than a bolt structure, but is the final cost going to be so enormous that I shouldn't even be looking at casting as a solution?

3. Is there job shops that will manufacture on-off castings in small amounts? If so, do I have to provide them with just the design of the part, and they will take care of the rest, or will I have to also design the casting molds etc?

4. Will a casted component hold up to the high dynamic forces, shock loads, vibrations the same or better to a bolted aluminum plate structure?. I am worried about cracking etc.

5. Please let me know of ANYTHING that I may be missing or misunderstanding.

Thanks in advance