Here's the summary first, so you can skip the rest if you want:
Consider what it would take to get the functionality out of Cosmos. If you decide to pursue Algor, ask for training when you purchase the product. The learning curve should be steep no matter where you go from here. I combine a variety of element types in virtually every model, but Cosmos can do this, too. You can definitely use your SolidWorks files. You can train yourself, but you shouldn't have to.
Here's the "wordy" version:
I've used Algor for about 10 years, but let me address the Cosmos comments first: Are you sure you couldn't just learn to use Cosmos a little better? It is a good package with much the same capability and it is integrated with SolidWorks because of their common parent company. The integration will only get better over time. It will use multiple element types, although the way it sounds like you are integrating may make it a little more difficult. I realize Cosmos/Works may be a little limited, but the packages comparable to Algor in cost are similar in capabilty. I do think Algor is the better value, but if you already have some Cosmos background, you may want to pursue it a little harder.
Now, because of my long-time contact with Algor, I may not be the best judge of "easy to learn", but I can say that the interface has improved remarkably over the last few years. FEA in general is getting more user-friendly...not that I'm comfortable with it getting too easy, but Algor does a fine job of linear static and thermal analyses with multiple element types. It integrates well with SolidWorks and is listed as a Solutions Partner on the SolidWorks website.
Training yourself or training via the web, considering your background with Cosmos, should come fairly easily no matter what package you pick up from here. If you purchase Algor, ask them to throw in a training class, or some one-on-one time with one of their techies via their web training capability. At a minimum, though, the learning curve will be pretty steep.
Meshing thin cross-sections is very easy. Basically, when you bring the CAD model in, you can set a thickness for midplane meshing in such a way that anything under a certain thickness with be mid-planed and anything over that thickness can be specified for solid elements. Including beam or truss elements is more of an after-the-fact meshing. You draw the line elements in after the plate modeling. Algor separates the SolidWorks parts into groups and surfaces that can be selected and manipulated.
Algor used to have a pre-processor named SuperDraw III. It had some features that have not been incorporated into FEMPRO, yet, but these features are more for convenience.
Call Algor: 1-800-482-5467 Tell them you are interested and that you spoke to one of Michael Miller's customers by the name of Garland Borowski...many of them know me. See if you can get a demo to test drive and determine the learning curve for yourself. Happy Shopping!
Garland E. Borowski, PE