Customised agile product shape development requires intelligent integration of multiple designers' inputs to fit various customer preferences. This study proposes a robust feature-based product modelling architecture for design customisation, which represents the product modelling processes as constrained morphing of relatively constant base feature with customised defined working features by subjecting to corresponding boundary constraints. The deformation on the surface patches of working features is adaptively controlled by the proposed energy-based solid mechanics surface model. The techniques on the construction of surface control network of springs, model segmentation, displacement computation of network nodes, as well as surface morphing processes are introduced in detail. The shape deformation process is uniformed across the surface control network, maintaining the shape being similar to its imported source pattern. This paper discusses examples and case study in footwear industry. The proposed method could be applied for customised product development in other related industries. Copyright © 2012 Inderscience Enterprises Ltd.