https://karaf.apache.org/manual/latest/kar contains:
As a KAR file is a simple zip file, you can create the KAR file by hand.
For instance, the following Unix commands create a very simple KAR file:
~$ mkdir repository
~$ cp /path/to/features.xml repository/features.xml
~$ cp /path/to/my.jar repository/my/project/my/1.0.0/my-1.0.0.jar
~$ zip -r my.kar repository
updating: repository/ (stored 0%)
adding: repository/my/project/my/1.0.0/my-1.0.0.jar (deflated 0%)
When I try the above example I see also a line adding: repository/feature.xml (deflated 53%). This line is missing from the output above.