branding: generate + wire real bear app icons (.icns/.ico/png) on all lanes

scripts/apply-bearbrowser-branding.sh

@@ -132,6 +132,19 @@ while IFS= read -r -d '' icon_dir; do
   [ "$icon_dirs_seen" -ge 50 ] && break
 done < <(find "$workspace" -type d \( -iname '*icon*' -o -iname '*branding*' -o -iname '*browser*' \) -print0)
 
+# Stage the pre-generated raster icon set (branding/icons/, built by
+# scripts/generate-brand-icons.sh) into the workspace so `make dir`
+# (scripts/bearbrowser-patches.py) can overwrite the librewolf-derived
+# browser/branding/bearbrowser rasters (.icns/.ico/sized .png) with the bear.
+# SVG-swapping alone (above) never changed the packaged app icons — the OSes
+# consume the rasters compiled into the branding dir, not the SVGs.
+if [ -d "$repo_root/branding/icons" ] && [ "$dry_run" != "true" ]; then
+  mkdir -p "$workspace/branding-icons"
+  cp "$repo_root/branding/icons/"* "$workspace/branding-icons/"
+  echo "branding-icons: staged $(ls "$repo_root/branding/icons" | wc -l | tr -d ' ') raster assets -> workspace/branding-icons/"
+  changed=$((changed + 1))
+fi
+
 # Ensure a BearBrowser app id marker exists for downstream package steps.
 if [ "$dry_run" != "true" ]; then
   mkdir -p "$workspace/.bearbrowser"

scripts/bearbrowser-package-source-build.sh

@@ -162,7 +162,18 @@ PY
 
 # ── Step 3: Install BearBrowser icon ─────────────────────────────────────────
 echo "[3/6] Installing BearBrowser icon..."
+# Info.plist sets CFBundleIconFile=BearBrowser, which macOS resolves to
+# Contents/Resources/BearBrowser.icns — an SVG is NOT a valid bundle icon, so
+# the .icns (generated by scripts/generate-brand-icons.sh) is the load-bearing
+# file here. The SVG is kept alongside for in-app/about uses.
+icon_icns="$repo_root/branding/icons/BearBrowser.icns"
 icon_svg="$repo_root/branding/bearbrowser.svg"
+if [ -f "$icon_icns" ]; then
+  cp "$icon_icns" "$out_app/Contents/Resources/BearBrowser.icns"
+  echo "      BearBrowser.icns installed (CFBundleIconFile target)"
+else
+  echo "      WARNING: $icon_icns not found — app will show a generic icon"
+fi
 if [ -f "$icon_svg" ]; then
   cp "$icon_svg" "$out_app/Contents/Resources/BearBrowser.svg"
   echo "      BearBrowser.svg installed"

scripts/bearbrowser-patches.py

@@ -133,6 +133,47 @@ def _strip_l10n_base(_path):
         _shutil.copytree(str(_lw_brand), str(_bb_brand))
         print(f"Created {_bb_brand} from {_lw_brand}")
 
+    # ── Bear icons: overwrite the librewolf-derived rasters ──────────────────
+    # The branding dir copied above still carries LibreWolf's raster icons —
+    # the files the OSes actually display (.icns compiled into the .app, .ico
+    # compiled into firefox.exe by rc, sized .png shipped for Linux). Overwrite
+    # them with the bear set staged by apply-bearbrowser-branding.sh
+    # (workspace/branding-icons/, generated from branding/bearbrowser.svg by
+    # scripts/generate-brand-icons.sh). Square .png slots are matched by their
+    # real IHDR pixel size (exact match only — never ship a wrong-size png);
+    # non-square art (wordmarks) is left alone.
+    _icons_src = Path("../branding-icons")
+    if _icons_src.is_dir() and _bb_brand.exists():
+        def _png_size(p):
+            try:
+                with open(p, "rb") as f:
+                    h = f.read(24)
+                if h[:8] != b"\x89PNG\r\n\x1a\n":
+                    return None
+                return (int.from_bytes(h[16:20], "big"), int.from_bytes(h[20:24], "big"))
+            except OSError:
+                return None
+        _icns = _icons_src / "BearBrowser.icns"
+        _ico = _icons_src / "bear.ico"
+        _replaced = 0
+        for _f in sorted(_bb_brand.rglob("*")):
+            if not _f.is_file():
+                continue
+            _suf = _f.suffix.lower()
+            if _suf == ".icns" and _icns.exists():
+                _shutil.copy(str(_icns), str(_f)); _replaced += 1
+            elif _suf == ".ico" and _ico.exists():
+                _shutil.copy(str(_ico), str(_f)); _replaced += 1
+            elif _suf == ".png":
+                _sz = _png_size(_f)
+                if _sz and _sz[0] == _sz[1]:
+                    _bear_png = _icons_src / f"bear-{_sz[0]}.png"
+                    if _bear_png.exists():
+                        _shutil.copy(str(_bear_png), str(_f)); _replaced += 1
+        print(f"-> Bear icons: replaced {_replaced} raster(s) in {_bb_brand}")
+    else:
+        print("note: ../branding-icons not staged — keeping librewolf rasters")
+
     # copy the right search-config.json file
     exec('cp -v ../assets/search-config.json services/settings/dumps/main/search-config.json')
 

scripts/generate-brand-icons.sh

@@ -0,0 +1,83 @@
+#!/usr/bin/env bash
+# generate-brand-icons.sh — rasterize branding/bearbrowser.svg into the platform
+# icon formats the OSes actually use, committed under branding/icons/:
+#
+#   bear-{16,32,48,64,128,256,512,1024}.png   (Linux window/desktop icons + sources)
+#   BearBrowser.icns                          (macOS app bundle icon)
+#   bear.ico                                  (Windows exe/installer icon, multi-size)
+#
+# Run manually on macOS after changing the SVG (uses qlmanage + iconutil + sips +
+# Pillow — all present on a stock dev Mac). CI never runs this; the build lanes
+# consume the committed assets (scripts/bearbrowser-patches.py overwrites the
+# librewolf-derived browser/branding/bearbrowser rasters with these).
+#
+# Gotcha encoded: qlmanage renders SVG at high quality but bakes an OPAQUE WHITE
+# background — the rounded-rect corners must be re-masked to transparent or the
+# icon ships with white corners. The mask radius mirrors the SVG (rx=112 at 512).
+set -euo pipefail
+
+repo_root="$(cd "$(dirname "${BASH_SOURCE[0]}")/.." && pwd)"
+svg="$repo_root/branding/bearbrowser.svg"
+out="$repo_root/branding/icons"
+[ -f "$svg" ] || { echo "ERROR: $svg missing" >&2; exit 1; }
+command -v qlmanage >/dev/null || { echo "ERROR: qlmanage (macOS) required" >&2; exit 1; }
+command -v iconutil >/dev/null || { echo "ERROR: iconutil (macOS) required" >&2; exit 1; }
+python3 -c 'import PIL' 2>/dev/null || { echo "ERROR: Pillow required (pip install Pillow)" >&2; exit 1; }
+
+mkdir -p "$out"
+tmp="$(mktemp -d)"
+trap 'rm -rf "$tmp"' EXIT
+
+echo "[1/4] Rendering SVG at 1024px (QuickLook)..."
+qlmanage -t -s 1024 -o "$tmp" "$svg" >/dev/null
+base="$tmp/$(basename "$svg").png"
+[ -f "$base" ] || { echo "ERROR: qlmanage produced no PNG" >&2; exit 1; }
+
+echo "[2/4] Masking rounded corners to transparent + generating PNG sizes..."
+python3 - "$base" "$out" <<'PY'
+import sys
+from PIL import Image, ImageDraw
+
+base_path, out = sys.argv[1], sys.argv[2]
+im = Image.open(base_path).convert("RGBA")
+w = im.width                      # 1024
+radius = round(112 / 512 * w)     # SVG: rx=112 on a 512 viewBox
+
+mask = Image.new("L", (w, w), 0)
+ImageDraw.Draw(mask).rounded_rectangle([0, 0, w - 1, w - 1], radius=radius, fill=255)
+im.putalpha(mask)
+
+for size in (16, 32, 48, 64, 128, 256, 512, 1024):
+    scaled = im if size == w else im.resize((size, size), Image.LANCZOS)
+    scaled.save(f"{out}/bear-{size}.png")
+    print(f"  bear-{size}.png")
+PY
+
+echo "[3/4] Building BearBrowser.icns (iconutil)..."
+iconset="$tmp/BearBrowser.iconset"
+mkdir -p "$iconset"
+cp "$out/bear-16.png"   "$iconset/icon_16x16.png"
+cp "$out/bear-32.png"   "$iconset/icon_16x16@2x.png"
+cp "$out/bear-32.png"   "$iconset/icon_32x32.png"
+cp "$out/bear-64.png"   "$iconset/icon_32x32@2x.png"
+cp "$out/bear-128.png"  "$iconset/icon_128x128.png"
+cp "$out/bear-256.png"  "$iconset/icon_128x128@2x.png"
+cp "$out/bear-256.png"  "$iconset/icon_256x256.png"
+cp "$out/bear-512.png"  "$iconset/icon_256x256@2x.png"
+cp "$out/bear-512.png"  "$iconset/icon_512x512.png"
+cp "$out/bear-1024.png" "$iconset/icon_512x512@2x.png"
+iconutil -c icns "$iconset" -o "$out/BearBrowser.icns"
+echo "  BearBrowser.icns"
+
+echo "[4/4] Building bear.ico (Pillow, multi-size)..."
+python3 - "$out" <<'PY'
+import sys
+from PIL import Image
+out = sys.argv[1]
+im = Image.open(f"{out}/bear-256.png")
+im.save(f"{out}/bear.ico", sizes=[(16,16),(24,24),(32,32),(48,48),(64,64),(128,128),(256,256)])
+print("  bear.ico")
+PY
+
+echo "Done → $out"
+ls -la "$out"