Ok, I did some digging. According to assetutil it seems like Assets.car contains an iconstack that has all the vector layers, color data etc for the glass icon and the traditional MultiSized Image with all the icon size variants for legacy macOS versions. In beta3 however (probably due to a bug) the MultiSized image variants were not created based on the Icon Composer image (only a single 1024x1024 variant was created). This gave way for the .incs file compiled into the app root to be taken as icon image on legacy macOS versions, which feeds from the proper xcassets icon file provided by the developer, not the Icon Composer generated pngs.
In beta4 this was "fixed", so now all size variants 16x16, 32x32...512x512 variants of the Icon Composer based MultiSize Image items are compiled into the Assets.car file - so macOS takes these now. Sadly there is no way to somehow replace these variants with the proper, developer supplied image or remove them (so the .incs file could be taken by legacy macOS versions instead) - the only tool assetutil that is given to manipulate .car files is extremely limited.
I really hope Apple will fix this. I don't see why it would be beneficial to entirely disregard the developer supplied App Icon asset and instead render (somewhat oddly looking) variants based on Icon Composer icons meant for glass (it should happen only if the developer does not provide custom App Icons suitable for older macOS versions).
An alternate solution would be to improve Icon Composer so it could take icon composition variants for legacy OS versions and the developer (so instead of only "watchOS" and "iOS/macOS" these should be a third "legacy iOS/macOS" option). This could at least enable developers to supply vector and bitmap images that match the legacy icon size/corner rounding. Also there should be a preview option in Icon Composer how the icon would look on older OS versions - the way that Icon Composer now "silently" produces entirely different looking variants for macOS 15 without a developer using Tahoe ever even seeing how it actually looks like is clearly not the right way to go.
Topic:
Developer Tools & Services
SubTopic:
Xcode
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