A method of determining the width of a nip formed by an industrial roll and a mating structure includes the steps of: providing an industrial roll having a cylindrical core and a polymeric cover surrounding the core, the industrial roll further comprising a plurality of pressure sensors mounted in the roll (optionally distributed in a helical pattern on the roll about a longitudinal axis of the roll); positioning the industrial roll in contact with the mating structure to form a nip; rotating the industrial roll; receiving pressure signals from the plurality of pressure sensors at a controller; and in the controller, utilizing the pressure signals from the pressure sensors to determine the width of the nip at locations on the roll associated with the pressure sensors.