PWM pushing 50 amps

Will this work?

In principle, yes.

What problems do you see?

  1. Availability of 4oz PCB, but you may have someone who will plate up to that;

  2. Stability of 4oz PCB if you can obtain it (making it flat an keeping it flat could be an issue on FR4);

  3. Switching losses with a simplistic gate drive; and

  4. The ease of causing fire or explosion when handling currents this big! Especially when commissioning the gate drive PWM functions ]:D.

suggestions to improve it?

a. Consider single-sided aluminium substrate PCB material for the MOSFET stage, like http://www.bergquistcompany.com/thermal_substrates/t-clad-product-overview.htm. I can connect you with a UK PCB manufacturer who specialises in this, but you may find one in NL;

b. If you have 12V available in your system, consider an active gate drive circuit, either using discrete transistors or an integrated bottom-switch driver. I'm using the UCC27533 on my current project, (see http://www.farnell.com/datasheets/1712835.pdf); and

c. Consider a high-speed over-current protection circuit, with a low-value sense resistor between source and Gnd and a comparator to sense an excessive voltage drop. I'm not so familiar with the MEGA family, but on the XMEGA I configure either in-chip fault protection functions, or events (faster versions of interrupts), to shut off the gate drive if the source current exceeds a safe limit.