This paper discusses the issues involved with creating a Tangible Augmented Reality representation of a product so that it can be effectively and validly used to support the product design process. The development of a TAR representation entails building the physical model of the product, a digital model of the product, and developing interactions between the digital and physical representations. Different products have different user interactions, which makes developing TAR representation for products challenging since a new interaction needs to be mimicked. Challenges of developing TAR representations are discussed by investigating TAR representations of four consumer products: a space heater, a MP3 player, an electric can opener, and a seat assist cushion. The goal of TAR representations is to not only communicate the functionality of a product but also to improve the time efficiency of prototyping of physical products. Hence, having a good understanding of the user interactions that need to be developed and planning the representation for construction in the modeling software and AR software is crucial to making the process of developing a TAR representation efficient.