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I don’t have the book yet and am wondering if there will be mutants of different sizes equalling the three different frame sizes? Is there AI frames as well? Would a humanoid frame be on a 30mm or should I still use 40mm? Thanks.

As long as your group decides what size bases they want to use and be consistent with the base sizes don't really matter. I'm planning on using 32 - 40mm for lights, 50-75mm meds, and anything larger than that for heavy frames (it lets me use my preexisting Tau and Ad Mech figs from 40K and scales pretty will with my Relic Knights and Infinity stuff too.)

I will start with 30mm and work my way up. I could see a few scenarios where light / small frames would be the only units used. Entering ruins and such come to mind.

Just a note if you don't have the book - all factions limit their number of lights to a max of 2. Mediums are really the workhorses it seems in this universe and you could put them on 50mm bases.

Well the rules are very open on this since the game is extremly open on the minis you use, basicly it is saying deside within your community.

However there is this official 20p intro booklet where they suggests light frames are 40-50mm bases and medium frames on 75-100mm bases.
https://drive.google.com/file/d/1Tmdf7JlrJlHlt6R8_wDKMyt6TqcvdX3q/view

Base sizes aside ...

Will there be mutants and AI factions?

First off, the factions are extremely open-ended. You could re-imagine any of them to fit pretty much any theme.

That said, one of the factions comprise pilotless frames. That faction is called Ghosts of Tiamat, where Tiamat was/is a sentient space station humans of the “before times” put into Earth-orbit in hopes that it could use nanobots to rebuild and clean the devastated atmosphere. Well, for whatever reasons, it became hostile instead and has now invaded Earth via gestalt-AI nanobot swarms. So the game comes packaged with a killer robot faction but you could very easily re-imagine it as a killer mutant faction.