The smart car is built at a factory complex called smartville, located at Hambach in Lorraine, France. Completed in October 1997, it is one of the most modern plants in the world. The car is designed to be highly modular, with modules / parts attached to a rigid integral "tridion" body frame. Design for assembly has received particular attention.

Assembly time is 4.5 hours. The basic frame of the car is powder-coated (not painted) - the colour is provided by dent-resistant plastic body panels which are designed to be changeable by the owner (as a fashion statement).