The Gingers were initially created by a friend of mine, Sue, who trades as Memories in Thread. I bought some of the designs from her, for others I tweaked her design, and in some cases I designed a completely new costume for her Gingers (using design skills I had learned from Sue when she used to teach the design software)
They are designed on the computer and then transferred to an Embroidery Machine. The stitching is automated but the operator (me) needs to rethread the machine for each new colour and trim the fabric off after it's been stitched. It's great fun to watch but the skill is probably more in the design work.
This video shows one of Sue's Gingers (having been slightly adapted by me) being stitched in time lapse photography
And I made a video showing a little of how the software works, but it is too big to embed in the blog, so here is the link to it showing part of a costume being created for a Memories in Thread Ginger:
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