Hyperspectral imaging (HSI) is an effective technique for material identification and classification, utilizing spectral signatures with applications in remote sensing, environmental monitoring, and allied disciplines. Despite its potential, the broader adoption of HSI technology is hindered by challenges related to compactness, affordability, and durability, exacerbated by the absence of standardized protocols for developing practical hyperspectral cameras. This study introduces a comprehensive framework for developing a compact, cost-effective, and robust hyperspectral camera, employing commercial off-the-shelf (COTS) components and a volume phase holographic (VPH) grism. The use of COTS components reduces development time and manufacturing costs while maintaining adequate performance, thereby improving accessibility for researchers and engineers. The incorporation of a VPH grism enables an on-axis optical design, enhancing compactness, reducing alignment sensitivity, and improving system robustness. The proposed framework encompasses spectrograph design, including optical simulations and tolerance analysis conducted in ZEMAX OpticStudio, alongside assembly procedures, performance assessment, and hyperspectral image acquisition via a pushbroom scanning approach, all integrated into a structured, step-by-step workflow. The resulting prototype, housed in an aluminum enclosure, operates within the 420–830 nm wavelength range, achieving a spectral resolution of 2 nm across 205 spectral bands. It effectively differentiates vegetation, water, and built structures, resolves atmospheric absorption features, and demonstrates the ability to distinguish materials in low-light conditions, providing a scalable and practical advancement in HSI technology.

Phosphorus (P) deficiency severely limits maize growth and yield, yet early detection remains challenging, as visible symptoms appear only after prolonged starvation. This study evaluated the capability of hyperspectral imaging (HSI) combined with machine learning to detect P deficiency in maize seedlings at both symptomatic and pre-symptomatic stages. Two greenhouse experiments were conducted: a long-term pot system under high and low P conditions and a short-term hydroponic experiment with three P concentrations of 500, 100, and 0 μmol/L phosphate (Pi). After long-term P deficiency, significant reductions in shoot biomass and Pi content were observed, while root biomass increased and nutrient profiles were altered. Hyperspectral signatures revealed distinct wavelength-specific differences across visible, red-edge, and near-infrared (NIR) regions, with P-deficient leaves showing lower reflectance in green and NIR regions but higher reflectance in the red band. A multilayer perceptron machine learning model achieved 99.65% accuracy in discriminating between P treatments. In the short-term experiment, P deficiency significantly reduced tissue Pi content within one week without affecting pigment composition or photosynthetic parameters. Despite the absence of visible symptoms, hyperspectral measurements detected subtle spectral changes, particularly in older leaves, enabling classification accuracies of 80.71–84.56% in the first week and 85.88–90.98% in the second week of P treatment. Conventional vegetation indices showed weak correlations with Pi content and failed to detect early P deficiency. These findings demonstrate that HSI combined with machine learning can effectively detect P deficiency before visible symptoms emerge, offering a non-destructive, rapid diagnostic tool for precision nutrient management in maize production systems.