Any time you equip an item in the character creator that has to be downloaded, the character simply will not load on another device or another user profile on the same device even though you are signed into the same MS account. Instead of checking whether you own the item and then downloading on that profile/device, it just refuses to let you edit the character. It will, however, allow you to delete the character. This is especially problematic when young family members share an MS login across different profiles on the same device, or on different devices. It also makes users who move to new devices have to recreate their characters.
Steps to reproduce
Log in to a Microsoft account in Minecraft.
In the character creator, unlock an item via purchase or achievement.
Equip the item.
Exit Minecraft.
Log in to another user profile on the same device, or go to another device.
Open Minecraft and log in to the same Microsoft account as in step (1).
Try to use or edit the character you made in step (3).
Expected result
Minecraft would let you use or edit the character you created because you are logged in to the same Microsoft account. Since you own the item that was equipped in step (3), it would download the item to the new profile/device if necessary to be able to load the character.
Observed result
"Failed to load character <X>". The "Reload" button does nothing, but "Delete Character" works.
Related issues
is duplicated by
relates to
Comments

This is due to the fact that parts of the player are downloaded to the device only after clicking on the item (for viewing). Approximately the same will happen if you clear the folder with player parts (premium_cache\persona).

I can confirm too that this issue happens all the time especially for split screen and multiple devices. I have been having this issue In split screen since 1.16 but only the main account outfit issue since 1.17 on my Xbox one

I wonder if this will actually get looked at and fixed

Is there any workaround? or should different device just use a different character?

That I can see nothing for Xbox I have tried pretty much everything I can and to no resolve

The explanation given by EVGENSYPERPRO above seems to be correct. A possible workaround might be to use one of your characters as a sandbox where you can edit it and select the items that need to be downloaded to that device, then back out, possibly restart the game, and use your preferred character.
This seems to have been fixed in 1.19. Anyone can confirm?
The game now automatically downloads the cache of character parts when launched with internet.

Yes, it is fixed for me. Resolving.
Can Confirm.