Thanks for all the comments. I have made some changes to my workflow and things are working better now.

"Inkscape" is a vector drawing program (which has beautifully designed icons). My canvas size of 28x22 points was a poor choice because the Cocoa frameworks would apply a non-uniform scale to it when what I wanted was no scaling. I have changed the canvas size to 32x32 points and now the pdf works great. The normal size toolbar image looks pixel perfect just as it was drawn. In "Inkscape" I have been drawing the vector graphics pixel aligned where possible.

The small toolbar image looks ok using the 32x32 point vector graphic pdf. I am not sure if it is worth my time right now to make a separate 24x24 point vector graphic for the small size.

I have completely eliminated the icns file. As per Paul Sanders comment, this is apparently used mainly for the application icon but is not appropriate for a toolbar icon. The pdf file works fine.

--Richard

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