Are there general expressions for $\sin(2^n x)$ and $\cos(2^n x)$ that only involve $\sin x$ and $\cos x$, and that moreover involve only polynomial (in $n$) number of terms?
Edit:
$2^n$ is not polynomial in $n$. A proof that no such expression exits (perhaps using the uniquness of Chebyshev polynomials?) would be gladly accepted.
If I understand the spirit of the question, no such expressions exist. First, $\cos(2^n \theta)$ is even, so a polynomial in $\sin \theta$ and $\cos \theta$ that is equal to $\cos(2^n \theta)$ contains only even powers of $\sin\theta$, and therefore may be written as a polynomial in $\cos\theta$, as marty cohen notes.
Now, $\cos(2^n \theta)$ has $2^{n+1}$ simple zeros in the interval $[0, 2\pi]$. By contrast, if $p_n$ is a polynomial with real coefficients and "polynomial-in-$n$ terms" (my interpretation of the original question), then $p_n$ has polynomial-in-$n$ roots in the interval $[-1, 1]$ by Descartes rule of signs, and consequently $p_n(\cos \theta)$ vanishes only polynomial-in-$n$ times in $[0, 2\pi]$.