Flutter not generating ios/Flutter/ephemeral/Flutter-Generated.xcconfig even in new project (macOS 15.5, Xcode 16.4, Flutter 3.32.5)

Description

I am unable to build Flutter iOS projects because the file
ios/Flutter/ephemeral/Flutter-Generated.xcconfig
is never generated, even after following all standard troubleshooting steps and even in a brand new project.

My environment:

• macOS: 15.5 (Sonoma)
• Xcode: 16.4
• Flutter: 3.32.5 (stable, also tried beta/master)
• Dart: 3.8.1
• CocoaPods: 1.16.2

What I’ve tried:

• Verified flutter and dart are from the same Flutter SDK (which flutter and which dart both point to /Users/myuser/development/flutter/bin/)
• flutter doctor shows no errors or warnings
• flutter pub get runs successfully (no errors)
• The ios/Flutter/ephemeral directory is created, but only contains flutter_lldb_helper.py and flutter_lldbinit
• The file Flutter-Generated.xcconfig is missing in both my main project and a brand new project created with flutter create test_new
• Tried flutter clean, flutter pub get, and flutter build ios --debug --no-codesign
• Checked permissions and disk space (all fine)
• Tried switching to Flutter beta and master channels, same result
• Reinstalled Flutter SDK from scratch
• No customizations to the iOS folder

Sample commands and output:

flutter clean
flutter pub get
ls ios/Flutter/ephemeral/Flutter-Generated.xcconfig
# Output: ls: ios/Flutter/ephemeral/Flutter-Generated.xcconfig: No such file or directory

Question:

• What could cause Flutter to not generate Flutter-Generated.xcconfig in any project, even with a clean install and correct environment?
• Are there any additional diagnostics or fixes I can try?
• Is this a known issue with recent macOS/Xcode/Flutter versions?

Any help or insight would be greatly appreciated!