btw, the air gap value is the magnetic air gap, a physical airgap will be half of that value.
I am switching at 1mhz with uHs.10mH will lead to about 1kHz switching frequency, and 5mH - 2kHz
At high current I some times use sync-diodes. (mosfet used as a diode) Synchronous rectificationSchottky diodes
my calculations at 100 volts in, 10 volts out and 100 amps at 1Khz and 1 volt drop across the switch, and 1 volt drop across the diode mean you're going to be running at about 10.2% duty cycle and for 10 amps of peak to peak ripple current means you need 505uH inductor. and its going to store 3 joules of energy.
I think you need isolation. It is dangerous to come off the power line without isolation.
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