With the increasing demand on the quality and productivity of miniaturized parts, fabrication of micro-parts directly using sheet metal is proven to be promising and efficient for mass production. This study aims at fabricating the micro-scaled cylindrical and meso-scaled flanged parts with good performance by directly using copper sheet metal. Progressive extrusion and blanking processes are conducted using optimized forming parameters, and the micro-scaled cylindrical part is fabricated via a shearing process, while the two-level flanged part is produced via progressive extrusion and blanking. To explore the effect of original microstructure on the deformation behavior and product quality of the formed part, the sheet metals were annealed with different heat treatment temperatures. The characteristics of the developed progressive forming system by directly using sheet metal are investigated, and the effects of grain size on dimensional accuracy, microstructure evolution and fracture behavior in the forming of both cylindrical and flanged parts are also explored. The findings of this research help improve the part quality and productivity in the fabrication of microparts via progressive forming directly using sheet metals.