The detail that surprised me most is that not a single screw or drop of glue holds these sawhorses together. Every joint is tapped home by hand with a rubber mallet, and the whole thing still stands up to a grown man doing dips and bouncing on it. For a knock-down design, that is a bold way to build.
The construction is where it gets clever for me. Aribabox cut every part from plywood sheet stock on a CNC router, and the precision of the machine means the pieces fit together perfectly. The joints are tight mortise and tenon style connections, with interlocking slotted base feet at the bottom, vertical upright posts carrying multiple rectangular adjustment slots, an arched horizontal frame with hook connectors, and a top capping rail to finish it off. After cutting, only assembly was left before the sawhorse was ready for work.
In use, the height changes between four settings from 70 cm up to 1 m, done by engaging the hooks into different slot levels on the uprights. The top rail also takes a wooden block secured with an F-clamp, giving a raised surface for sawing or chisel work. A large tabletop panel sat across the pair to show the setup in action.
My open question is longevity: how those slot edges and notches cope with years of daily knocking, and whether the bottom notches stay put on uneven ground. It also seems fair to say that reproducing this design needs CNC access, which not every shop has, so the idea travels less easily than the sawhorses themselves.
Project by Aribabox. Watch it on their YouTube channel: