Thomas was alone has a great set of characters that look all like squares, but are all uniques and appealing thanks to their personalities. Colors and shape are just here to differentiate them. We can say the same for comics like xkcd or even Peanuts, where (almost) only accessories, clothes and hairs help to recognize characters that are defined by their personalities.
The Scythian from Sword and Sworcery EP is also a great example of character writing: the character is so pixelated that we can't really see much about her, and she literally has no back-story… But it's her actions in the game that build her character, and allows to see who she is! It's a character defined not by what she did, but what she does.
And anyway, in literature, if you think about it, there's not really strong characters design. Sure, the author can write a description of its characters, but it's not uncommon to see some characters appearances let to the reader's imagination. Some characters are awesome because of who they are instead of how they look like.
Although, the look comes as primordial when you consider multiplicity. Characters have to be different to each other, not only for a practical reason (I hate those movies where every actors and actress look exactly like the same model of perfection) (I'M LOOKING AT YOU PACIFIC RIM), but also for the universe's depth. A world with only one kind of people is boring, not credible, and in the worst case exclusive. That's where diversity comes in handy! \o/ Characters must have main traits that define them in the story, but also secondary one that aren't pertinent, but make them more complex, unique, and overall likable. Even if it's not the definition of a character, it's always good, as an author, to gives some supplementary aspects, as long as it's not in contradiction with what they are.
Generally, I try to write arbitrarily some of my characters into women, even if I imagined them as men. Since their main aspect wasn't masculinity (for most), it works most of the time, and give a set of characters richer than what I attended. And it's even better when I give a character Russian origins, another one short legs, or when I add some different colors, accents, age, weight, physical handicaps… It's a way to make them identifiable, and to create a universe only made of people like myself.
So basically, that's the order I chose to create characters: first, the personality, its story, the main definition of who they are.
Then, I add to them aspects, traits, optional details, that allow to make them recognizable in the cast. Those aspects are made in function of the others: I don't want two characters to look alike, so I make them different. But who they are they are is for the most part independent of how they look like.
Well, more exactly: who they were when I first write them. It's an evidence that adding those traits have an influence on the character itself. But it doesn't change the core, and make even in the end a new character built from several ideas. And that's something I find very interesting: discovering my own characters as I assemble them!