I haven't given any thought to treb design for more than a decade. Yes, I am an experienced trebuchet builder with published pictures of examples.
Period Machines: I think that we've seen the best of them come and go. Were I to mount a campaign of conquest using trebuchet, you can bet your last dollar that my engineers would have the design figured out. Logically, that means that there was a lot of military research and development that we will never read about. The plans didn't come to them in a dream. Even the angle of the sling finger for proper release. The size limit might be reached by several things: the modulus of elasticity of woods available for the arm. Laminations are certainly superior to a log. They would have known that from long bow construction, even the correct orientation of the growth rings. Friction on the slide with the sling basket. Grease can only do so much. For my part, a little 5W30 motor oil on axle parts has quite a dramatic effect. Inertia = how do you get the mass of the projectile to even begin to move? A rock would have fewer and more intensly confined pressure points on the slide, than a horse.
Modern Machines: I am not, nor ever was, a materials engineer. As parts of university dendrology courses, I did teach the fundamentals of mechanical and non mechanical properties as they apply to wood. Look for specifics on your own time.
What would I try, from the materials I'm aware of?
Arm: Boron-doped, carbon fiber lay up. The design might be eliptical in XS, the long/strong axis parallel to the plane of rotation. Roller bearings. ball bearings (which is best?) for the two axle points.
Swinging counterweight, made of and loaded with the densest element in the Periodic Table (can't find my reference book but I know for sure it isn't Uranium.)
Limits: Besides friction on the slide (travelling carriage?), overcoming the inertia of the projectile is not going to go away.
Risks: The counterweight is falling due to gravity as the arm begins its rotation. When the sling loop comes off the finger and the projectile is released, the arm does not come to a sudden freakin' halt.
The overtravel goes into quite violent recoil oscillations (very disconcerting if you aren't ready for it.)
As you know from reading, both the arm and the counterweight are flapping about. This is where I think that the failure will occur.
Desires: give me an automated disk brake damping system on the arm/counterweight pivot point. It's delayed beyond the release of the sling loop from the finger.
If it wasn't my money, I'd try an arm, 60' total. The tower and slide are not an issue. Loading would be least risky by lifting the counterweight, not pulling down on the arm. You've seen those people-powered wind-up mechanisms? Why do you suppose they went that way in the design? Huh? What did they break most easily? It is one big Hello of a surprise when the arm breaks. Cable trigger, not some box-latch screw-up. Can you imagine an iron counterweight and an electromagnetic latch?
Find a materials engineer, young person. Bring them up to speed and pitch the same question to them.