I have never seen a book using a purely geometric definition but it can be done. I will try to give you the outline of such an approach and if you wish I can send you a pdf file I am currently writing for the details.
Actually in some way the rigorous approach is just the intuitive approach, so let us take a look at the intuitive approach and try to fix it's problems. To get $(\cos(x), \sin(x))$ by the intuitive approach lets proceed as follows:
Take the point $z$ on the circle which is at an arc length of $x$ from $(1, 0)$ in the direct orientation and then define $\cos(x) = p_1(z)$ and $\sin(x) = p_2(z)$ where $p_1$ and $p_2$ are the projections.
The problem of this intuitive approach is that many of the terms used are undefined and it is unclear if such a point $z$ exists or is unique. The first step is to define what is arc length, to do so we define what is the length of a curve this is done here: https://en.wikipedia.org/wiki/Arc_length. The second step would be to define what it means to be directly oriented, to avoid using differential geometry we can use this simple definition: a differentiable curve $\gamma \in \mathcal{C}([a, b], \mathcal{S}^1)$ is said to be directly oriented if: $\forall t \in [a, b], \det(\gamma(t), \gamma'(t)) > 0$. Now suppose that there is $\gamma \in \mathcal{C}([a, b], \mathcal{S}^1)$ such that the following are true:
- $\gamma$ is $\mathcal{C}^1$ by parts.
- $\gamma([a, b]) = \mathcal{S}^1$
- $\gamma$ is a simple loop.
- $\gamma$ is directly oriented.
- $\gamma(a) = (1, 0)$
Using such a curve $\gamma$ we can now define the functions $\cos$ and $\sin$ and we shall proceed by keeping the idea of the intuitive definition. First given an $x \in [a, b]$ we should find a point $z$ on the circle which is at an arc length of $x$ from $(1, 0)$ in the direct orientation. To do so we can consider the function $f(x) = Length(\gamma \lvert_{[a, x]}) = \underset{[a, x]}{\int} \lVert \gamma'(t) \rVert d \lambda(t)$ and notice that singe $\gamma$ is directly oriented $\gamma'(x) \neq 0$ thus $f'(x) = \lVert \gamma'(x) \rVert > 0$ means that $f$ is a diffeomorphism. Thus the point $z$ would be given by $z = \gamma(f^{-1}(x))$ and now by using the projections $p_i$ we can define:
$$\cos(x) = p_1 \circ \gamma \circ f^{-1}(x)$$
$$\sin(x) = p_2 \circ \gamma \circ f^{-1}(x)$$
We can also prove this definition is independent of $\gamma$. And you may ask that here we used the fact that such a $\gamma$ exists but how do we prove it? To do so we may just use the equation $x^2 + y^2 = 1$ and obtain curves that look like $\alpha(t) = \left(t , (1 - t^2)^{\frac{1}{2}} \right)$ and them "stick" them together to obtain the wanted curve.
This definition is very close to the intuitive definition however to prove the theorems you need something a bit better, bellow I will offer an other definition that still keeps this geometric spirit but is easier to use for proving things. It is based on the following result:
For every $z \in \mathcal{S}^1$ there is a unique curve that we will call $trig_z \in \mathcal{C}([0, a], \mathcal{S}^1)$ which verifies all the following:
- $trig_z$ is $\mathcal{C}^1$ and is a simple loop
- $trig_z(0) = z$
- $trig_z([0, a]) = \mathcal{S}^1$
- $trig_z$ is directly oriented
- $\lVert trig_z'(x) \rVert = 1$
Of course to prove the previous result no trigonometry is needed but the proof is not so simple. After by defining $trig = trig_{(1, 0)}$ then we can define:
$$\cos = p_1 \circ trig$$
$$\sin = p_2 \circ trig$$
Using $trig$ you can prove all the results, for example to get the differentials of $\cos$ and $\sin$ you can differentiate the equation:
$$\cos(x)^2 + \sin(x)^2 = 1$$
Or use the fact that $trig'(x)$ must be in the tangent line $T_x \mathcal{S}^1$ of $\mathcal{S}^1$.
You can also prove the $\cos(x + y)$ and $\sin(x + y)$ formulas by defining $\gamma(y) = \cos(y) trig(x) + \sin(y) trig'(x)$ we can check that $\gamma(0) = trig(x)$ and $\gamma$ has all the required properties to apply our uniqueness result and we obtain that $\gamma = trig_{trig(x)}$.
And we can also show that $trig_{trig(x)} = trig(\cdot + x)$. Thus by noticing that $trig'(x) = (- \sin(x), \cos(x))$ and using that $\gamma = trig{\cdot + x}$ we obtain the wanted formulas.
Using such techniques you can prove everything, well at least for everything I tried to prove, I was able to.
I hope this replies to your question and helped you.