Thank you for the detailed explanation Don. Do I understand correctly that passive low-pass filter (e.g. several resistors and capacitors, not transistors) after the amp itself will make the amp's performance worse and hence not used in production?
It would increase the output impedance and interact with the crossover in the speakers (which is also a passive filter unless you are connecting directly to the drivers). "Worse", who knows, but I would not do it. I don't think it is needed and would just add more reactance to the load. The power level of a noise spike 60 dB below full scale is very low and the frequency is way beyond what any speaker is going emit. I would guess parasitic capacitance in the crossover and voice coil, plus inductance of the voice coil itself, will knock that waaay down so even less power reaches the speaker's cone. I.e. negligible.
Note there is already a passive LC low-pass filter inside the amp; otherwise, that switching spur would be much higher. FWIWFM, the output filters in all the class-D amps I have seen, and any additional filter I might add, are LC designs with any resistance (R) being parasitic. Look at the one in the the thread I linked here on AVS; that simple design uses a second-order LC filter at the output as that is what I have seen most often in the few commercial products I have seen.
I have active speakers with RCF ND 950 compression drivers and there is definitely more noise when powered with a class D Pioneer amp (International Rectifier module). The noise is so loud, I had to make an 20dB L-Pad. 3 out of 4 A/B amps I tried were very quiet and didn't need an L-Pad.
I suppose that high frequence noise induce sub-harmonics of some kind that we can easily hear.
I strongly suspect the extra in-band noise is just a reflection of the overall amplifier design and performance rather than switching noise mixing down someplace in the speaker. It could be getting coupled and mixed/rectified inside the amp; that would be a poor design and/or layout. There are plenty of very quiet (high SNR) class-D amplifiers around. That said, high-sensitivity compression drivers are where low SNR is going to create noise, be it class A, AB, D, or anything else. Most often when a fairly high-powered amplifier drives a high-sensitivity driver; that is a common mismatch leading to hiss. An L-pad or similar is a common fix, or even a small series R to attenuate the signal to the driver. Or as you imply just use a different amplifier.