Since I asked the question, I came up with the following solution, which, I think, may be the most beautiful formalisation of a proof of the Euler's formula. It only works, however, if we assume that we already know that $e^{2\pi i} = 1$. If anyone can find a simple proof of this that does not use Euler, say so.
We consider the curve $\gamma\colon\Bbb R\to\Bbb C$ given by $\gamma(t) = e^{it}$ for all $t\in\Bbb R$. It is obviously smooth because $\exp$ is. We define $\cos$ and $\sin$ by Euler's formulas.
Lemma 1: $\gamma$ is a parametrization of a part of the complex unit circle $S^1$.
Proof: We have $\lvert \gamma(t)\rvert =\gamma(t)\overline{\gamma(t)}= e^{it}e^{-it} = e^0 = 1$.
Lemma 2: $\gamma$ is $2\pi$-periodic.
Proof: Since $e^{it}e^{is} = e^{i(t+s)}$ for all $s,t\in\Bbb R$, it follows from the fact that $e^{2\pi i} = 1$, which we assumed to know. (We haven't proved, however, that $\gamma$ could not have a shorter period).
Lemma 3: $\gamma$ paremetrizes all of the unit circle.
Proof: Let $p\in S^1$ be a point on the unit circle. We must show that $\gamma$ hits $p$. Since $\overline{\gamma(t)} = \gamma(-t)$ for all $t\in\Bbb R$, we may assume without loss of generality that the imaginary part of $\gamma$ is $\ge 0$, hence $p\in S^1_+ = \{s\in S^1\mid\operatorname{Im}(s)\ge 0\}$, the upper complex unit circle. It is not hard to show that all points on $S^1_+$ are uniquely determined by their real values, hence we only have to show that $\operatorname{Re}(\gamma)$ takes the value $r:=\operatorname{Re}(p)$. Now the real part $\operatorname{Re}(\gamma)$ is a smooth function $\Bbb R\to [-1,1]$ with $\gamma(0) = 1$, so if it does not take the value $r$ on $[0,2\pi)$, $\operatorname{Re}(\gamma)$ must have a lower bound, hence $\operatorname{Re}(\gamma)(t)\ge b$ for alle $t$ for some $b\in(-1,1)$ (if $b = -1$, $\operatorname{Re}(\gamma)$ would be surjective onto $[-1,1]$ by continuity, which is a contradiction). This is also true for the restriction of $\gamma$ to the compact set $[0,2\pi]$, hence $\operatorname{Re}(\gamma(s)) = b$ for some $s\in[0,2\pi)$. Then $\operatorname{Re}(\gamma'(s)) = 0$. But $\gamma$ has the constant absolute value 1, hence $\gamma$ and $\gamma'$ are perpendicular (differentiate $1 = \langle\gamma,\gamma\rangle$ and get $0 = 2\langle\gamma',\gamma\rangle$); but the only points on $S^1_+$ with a purely imaginary tangent vector are $\pm i$. Hence $p$ is perpendicular to $\pm i$. But this implies that $p = \pm 1$. $p$ obviously cannot be $1$, and if $p = -1$, the same continuity argument as before shows that $\operatorname{Re}(\gamma)$ is surjective onto $[-1,1]$. In either case, we get a contradiction.
Definition 4: Let $p\in S^1$. The angle of $p$ is the (minimal) number $\theta$ in $[0,2\pi)$ such that $\gamma(\theta) = p$.
Now $\cos(\theta)$ and $\sin(\theta)$ are the real and imaginary parts of the number $p$, by definition of $\cos$ and $\sin$. Notice that our definition of angle does not rely on the arc length as defined by integration methods. It is, however, consistent with the angle as defined through arc lengths:
Proposition 5: The angle of a point $p\in S^1$ is the arc length from $1$ to $p$.
Proof: The arc length is, by definition, the length of any surjective smooth curve on $S^1$ from $1$ to $p$; $\gamma\big|_{[0,\theta]}$ is such a curve, where $\theta$ is the angle of $p$. We have that the length of $\gamma\big|_{[0,\theta]}$ is
$$
\ell(\gamma\big|_{[0,\theta]}) = \int_0^\theta\lVert\gamma'\rVert d t = \int_0^\theta 1 d t = \theta.
$$
Hence we have gone from the complex exponential function to the arc length on the unit circle, which was what I requested. Thus if someone has a good argument that $e^{2\pi i} = 1$, we are done.