We report on experimental generation of a 6.8 μJ laser pulse spanning from 1.8 to 4.2 μm from cascaded second-order nonlinear processes in a 0.4-mm BiB3O6 (BIBO) crystal. The nonlinear processes are initiated by intra-pulse difference frequency generation (DFG) using spectrally broadened Ti:Sapphire spectrum, followed by optical parametric amplification (OPA) of the DFG pulse. The highest energy, 12.6 μJ, is achieved in a 0.8-mm BIBO crystal with a spectrum spanning from 1.8 to 3.5 μm. Such cascaded nonlinear processes are enabled by the broadband pump and the coincident phase matching angle of DFG and OPA. The spectrum is initiated from the DFG process and is thus expected to have passive stable carrier-envelope phase, which can be used to seed either a chirped pulse amplifier (CPA) or an optical parametric chirped pulse amplifier (OPCPA) for achieving high-energy few-cycle mid-infrared pulses. Such cascaded second-order nonlinear processes can be found in many other crystals such as KTA, which can extend wavelengths further into mid-infrared. We achieved a 0.8 μJ laser pulse spanning from 2.2 to 5.0 μm in KTA.