Jimbonic,
I thought about your system some more, and had another idea. You might want to try using an external firewire hard drive connected to the CVS. Writing to these drives is MUCH faster than trying to write to the CompactFlash on the CVS, which is honestly pretty slow.
Also, in regards to your question about what image type to process, you don't really process on a bmp or a png, but only use those types for storing the images. When you do the image processing in VBAI or LabVIEW, you're really just processing an allocated image buffer as opposed to a file.
Saving just failed images is certainly something that VBAI can do, although I'm a little confused as to how you want to separate just one image here. Tell me if I'm wrong, but here's how I see your application: You have 3 images upon which you are doing some inspection on a single object. If one of the images fails, then that object fails and you are currently logging all 3 of those images to file. Let's say just one of the images fails, therefore failing the inspection, you would like to log just that image that failed and not all three?
Regards,
Dan
National Instruments