Federated learning, a pioneering paradigm, enables collaborative model training without exposing users’ data to central servers. Most existing federated learning systems necessitate uniform model structures across all clients, restricting their practicality. Several methods have emerged to aggregate diverse client models; however, they either lack the ability of personalization, raise privacy and security concerns, need prior knowledge, or ignore the capability and functionality of personalized models. In this paper, we present an innovative approach, named pFedClub, which addresses these challenges. pFedClub introduces personalized federated learning through the substitution of controllable neural network blocks/layers. Initially, pFedClub dissects heterogeneous client models into blocks and organizes them into functional groups on the server. Utilizing the designed CMSR (Controllable Model Searching and Reproduction) algorithm, pFedClub generates a range of personalized candidate models for each client. A model matching technique is then applied to select the optimal personalized model, serving as a teacher model to guide each client’s training process. We conducted extensive experiments across three datasets, examining both IID and non-IID settings. The results demonstrate that pFedClub outperforms baseline approaches, achieving state-of-the-art performance. Moreover, our model insight analysis reveals that pFedClub generates personalized models of reasonable size in a controllable manner, significantly reducing computational costs